Sanitary Tissue Products

ABSTRACT

Sanitary tissue products employing fibrous structures that exhibit novel compressibility properties alone and in combination with plate stiffness properties and methods for making same.

FIELD OF THE INVENTION

The present invention relates to sanitary tissue products comprisingfibrous structures that exhibit a novel combination of cushiness asevidenced by compressibility of the sanitary tissue products andflexibility as evidenced by plate stiffness of the sanitary tissueproducts and methods for making same.

BACKGROUND OF THE INVENTION

Cushiness and flexibility, both characteristics associated with cloths,are attributes that consumers desire in their sanitary tissue products,for example bath tissue products. A technical measure of cushiness iscompressibility of the sanitary tissue product which is measured by theStack Compressibility and Resilient Bulk Test Method. A technicalmeasure of flexibility is plate stiffness of the sanitary tissue productwhich is measured by the Plate Stiffness Test Method. Current sanitarytissue products fall short of consumers' expectations for cushiness andflexibility.

Accordingly, one problem faced by sanitary tissue product manufacturersis how to improve (i.e., increase) the compressibility properties andimprove (i.e., decrease) the plate stiffness properties of sanitarytissue products, for example bath tissue products, to make such sanitarytissue products cushier and more flexible to better meet consumers'expectations for more clothlike, luxurious, and plush sanitary tissueproducts.

Accordingly, there exists a need for sanitary tissue products, forexample bath tissue products, that exhibit improved compressibilityproperties and improved plate stiffness properties to provide consumerswith sanitary tissue products that fulfill their desires andexpectations for more comfortable and/or luxurious sanitary tissueproducts, and methods for making such sanitary tissue products.

SUMMARY OF THE INVENTION

The present invention fulfills the need described above by providingsanitary tissue products, for example bath tissue products, that arecushier and more flexible than known sanitary tissue products, forexample bath tissue products, as evidenced by improved compressibilityas measured according to the Stack Compressibility and Resilient BulkTest Method and improved plate stiffness as measured according to thePlate Stiffness Test Method, and methods for making such sanitary tissueproducts.

One solution to the problem set forth above is achieved by making thesanitary tissue products or at least one fibrous structure ply employedin the sanitary tissue products on patterned molding members that impartthree-dimensional (3D) patterns to the sanitary tissue products and/orfibrous structure plies made thereon, wherein the patterned moldingmembers are designed such that the resulting sanitary tissue products,for example bath tissue products, made using the patterned moldingmembers are cushier and more flexible than known sanitary tissueproducts as evidenced by the sanitary tissue products, for example bathtissue products, exhibiting compressibilities that are greater than(i.e., greater than 36 mils/(log(g/in²)) and/or greater than 46mils/(log(g/in²))) the compressibilities of known sanitary tissueproducts, for example bath tissue products, as measured according to theStack Compressibility and Resilient Bulk Test Method and platestiffnesses that are less than (i.e., less than 8.3 N*mm and/or lessthan 5.2 N*mm) the plate stiffnesses of known sanitary tissue products,for example bath tissue products, as measured according to the PlateStiffness Test Method. Non-limiting examples of such patterned moldingmembers include patterned felts, patterned forming wires, patternedrolls, patterned fabrics, and patterned belts utilized in conventionalwet-pressed papermaking processes, air-laid papermaking processes,and/or wet-laid papermaking processes that produce 3D patterned sanitarytissue products and/or 3D patterned fibrous structure plies employed insanitary tissue products. Other non-limiting examples of such patternedmolding members include through-air-drying fabrics andthrough-air-drying belts utilized in through-air-drying papermakingprocesses that produce through-air-dried sanitary tissue products, forexample 3D patterned through-air dried sanitary tissue products, and/orthrough-air-dried fibrous structure plies, for example 3D patternedthrough-air-dried fibrous structure plies, employed in sanitary tissueproducts.

In one example of the present invention, a sanitary tissue productcomprising a plurality of pulp fibers, wherein the sanitary tissueproduct exhibits a Compressibility of greater than 46 mils/(log(g/in²))as measured according to the Stack Compressibility and Resilient BulkTest Method and a Plate Stiffness of less than 5.2 N*mm as measuredaccording to the Plate Stiffness Test Method, is provided.

In another example of the present invention, a sanitary tissue productcomprising at least one 3D patterned fibrous structure ply comprising aplurality of pulp fibers, wherein the sanitary tissue product exhibits aCompressibility of greater than 46 mils/(log(g/in²)) as measuredaccording to the Stack Compressibility and Resilient Bulk Test Methodand a Plate Stiffness of less than 5.2 N*mm as measured according to thePlate Stiffness Test Method, is provided.

In yet another example of the present invention, a sanitary tissueproduct, for example bath tissue product, comprising at least one crepedthrough-air-dried fibrous structure ply comprising a plurality of pulpfibers, wherein the sanitary tissue product exhibits a Compressibilityof greater than 36 mils/(log(g/in²)) as measured according to the StackCompressibility and Resilient Bulk Test Method and a Plate Stiffness ofless than 5.2 N*mm as measured according to the Plate Stiffness TestMethod, is provided.

In even another example of the present invention, a multi-ply, forexample two-ply, sanitary tissue product, for example bath tissueproduct, comprising a plurality of pulp fibers, wherein the multi-plysanitary tissue product exhibits a Compressibility of greater than 36mils/(log(g/in²)) as measured according to the Stack Compressibility andResilient Bulk Test Method and a Plate Stiffness of less than 5.2 N*mmas measured according to the Plate Stiffness Test Method, is provided.

In even yet another example of the present invention, a multi-ply, forexample two-ply, sanitary tissue product, for example bath tissueproduct, comprising at least one 3D patterned fibrous structure ply, forexample a 3D patterned through-air-dried fibrous structure ply,comprising a plurality of pulp fibers, wherein the multi-ply sanitarytissue product exhibits a Compressibility of greater than 36mils/(log(g/in²)) as measured according to the Stack Compressibility andResilient Bulk Test Method and a Plate Stiffness of less than 5.2 N*mmas measured according to the Plate Stiffness Test Method, is provided.

In even yet another example of the present invention, a multi-plysanitary tissue product comprising at least one creped through-air-driedfibrous structure ply comprising a plurality of pulp fibers, wherein thesanitary tissue product exhibits a Compressibility of greater than 36mils/(log(g/in²)) as measured according to the Stack Compressibility andResilient Bulk Test Method and a Plate Stiffness of less than 8.3 N*mmas measured according to the Plate Stiffness Test Method.

In yet another example of the present invention, a multi-ply sanitarytissue product comprising a plurality of pulp fibers, wherein thesanitary tissue product exhibits a Compressibility as measured accordingto the Stack Compressibility and Resilient Bulk Test Method and a PlateStiffness as measured according to the Plate Stiffness Test Method suchthat the sanitary tissue product is above a line having the followingequation: y=1.5152x+43.061 graphed on a plot of Compressibility to PlateStiffness as shown in FIG. 1A, is provided.

In yet another example of the present invention, a multi-ply bath tissueproduct, for example a bath tissue product that exhibits a sum of MD andCD dry tensile of less than 1000 g/in, comprising at least one crepedthrough-air-dried fibrous structure ply comprising a plurality of pulpfibers, wherein the sanitary tissue product exhibits a Compressibilityof greater than 36 mils/(log(g/in²)) as measured according to the StackCompressibility and Resilient Bulk Test Method, is provided.

In still yet another example of the present invention, a method formaking a single- or multi-ply sanitary tissue product according to thepresent invention, wherein the method comprises the steps of:

-   -   a. contacting a patterned molding member with a fibrous        structure comprising a plurality of pulp fibers such that a 3D        patterned fibrous structure ply is formed;    -   b. making a single- or multi-ply sanitary tissue product        according to the present invention comprising the 3D patterned        fibrous structure ply, is provided.

Accordingly, the present invention provides sanitary tissue products,for example bath tissue products, that are cushier and more flexiblethan known sanitary tissue products, for example bath tissue products,and methods for making same.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a plot of Compressibility (mils/(log(g/in²))) to PlateStiffness (N*mm) for sanitary tissue products of the present inventionand commercially available sanitary tissue products, both single-ply andmulti-ply sanitary tissue products, illustrating the high level ofCompressibility and the low level of Plate Stiffness exhibited by thesanitary tissue products, for example bath tissue products, of thepresent invention;

FIG. 1B is a plot of Compressibility (mils/(log(g/in²))) to Slip StickCoefficient of Friction (COF*10000) for sanitary tissue products of thepresent invention and commercially available sanitary tissue products,both single-ply and multi-ply sanitary tissue products, illustrating thehigh level of Compressibility and the low level of Plate Stiffnessexhibited by the sanitary tissue products, for example bath tissueproducts, of the present invention;

FIG. 2A is a schematic representation of an example of a molding memberaccording to the present invention;

FIG. 2B is a further schematic representation of a portion of themolding member of FIG. 2A;

FIG. 3 is a MikroCAD image of a sanitary tissue product made using themolding member of FIG. 2A;

FIG. 4A is a schematic representation of another example of a moldingmember according to the present invention;

FIG. 4B is a further schematic representation of a portion of themolding member of FIG. 4A;

FIG. 4C is a cross-sectional view of FIG. 4B taken along line 4C-4C;

FIG. 5A is a schematic representation of a sanitary tissue product madeusing the molding member of FIG. 4A;

FIG. 5B is a cross-sectional view of FIG. 5A taken along line 5B-5B;

FIG. 5C is a MikroCAD image of a sanitary tissue product made using themolding member of FIG. 4A;

FIG. 5D is a magnified portion of the MikroCAD image of FIG. 5C;

FIG. 6A is a schematic representation of another example of a moldingmember according to the present invention;

FIG. 6B is a further schematic representation of a portion of themolding member of FIG. 6A;

FIG. 6C is a cross-sectional view of FIG. 6B taken along line 6C-6C;

FIG. 7A is a MikroCAD image of a sanitary tissue product made using themolding member of FIG. 6A;

FIG. 7B is a magnified portion of the MikroCAD image of FIG. 7A;

FIG. 8 is a schematic representation of an example of athrough-air-drying papermaking process for making a sanitary tissueproduct according to the present invention;

FIG. 9 is a schematic representation of an example of an uncrepedthrough-air-drying papermaking process for making a sanitary tissueproduct according to the present invention;

FIG. 10 is a schematic representation of an example of fabric crepedpapermaking process for making a sanitary tissue product according tothe present invention;

FIG. 11 is a schematic representation of another example of a fabriccreped papermaking process for making a sanitary tissue productaccording to the present invention;

FIG. 12 is a schematic representation of an example of belt crepedpapermaking process for making a sanitary tissue product according tothe present invention;

FIG. 13 is a schematic top view representation of a Slip StickCoefficient of Friction Test Method set-up;

FIG. 14 is an image of a friction sled for use in the Slip StickCoefficient of Friction Test Method; and

FIG. 15 is a schematic side view representation of a Slip StickCoefficient of Friction Test Method set-up.

DETAILED DESCRIPTION OF THE INVENTION Definitions

“Sanitary tissue product” as used herein means a soft, low density (i.e.<about 0.15 g/cm³) article comprising one or more fibrous structureplies according to the present invention, wherein the sanitary tissueproduct is useful as a wiping implement for post-urinary and post-bowelmovement cleaning (toilet tissue), for otorhinolaryngological discharges(facial tissue), and multi-functional absorbent and cleaning uses(absorbent towels). The sanitary tissue product may be convolutedlywound upon itself about a core or without a core to form a sanitarytissue product roll.

The sanitary tissue products and/or fibrous structures of the presentinvention may exhibit a basis weight of greater than 15 g/m² to about120 g/m² and/or from about 15 g/m² to about 110 g/m² and/or from about20 g/m² to about 100 g/m² and/or from about 30 to 90 g/m². In addition,the sanitary tissue products and/or fibrous structures of the presentinvention may exhibit a basis weight between about 40 g/m² to about 120g/m² and/or from about 50 g/m² to about 110 g/m² and/or from about 55g/m² to about 105 g/m² and/or from about 60 to 100 g/m².

The sanitary tissue products of the present invention may exhibit a sumof MD and CD dry tensile strength of greater than about 59 g/cm (150g/in) and/or from about 78 g/cm to about 394 g/cm and/or from about 98g/cm to about 335 g/cm. In addition, the sanitary tissue product of thepresent invention may exhibit a sum of MD and CD dry tensile strength ofgreater than about 196 g/cm and/or from about 196 g/cm to about 394 g/cmand/or from about 216 g/cm to about 335 g/cm and/or from about 236 g/cmto about 315 g/cm. In one example, the sanitary tissue product exhibitsa sum of MD and CD dry tensile strength of less than about 394 g/cmand/or less than about 335 g/cm.

In another example, the sanitary tissue products of the presentinvention may exhibit a sum of MD and CD dry tensile strength of greaterthan about 196 g/cm and/or greater than about 236 g/cm and/or greaterthan about 276 g/cm and/or greater than about 315 g/cm and/or greaterthan about 354 g/cm and/or greater than about 394 g/cm and/or from about315 g/cm to about 1968 g/cm and/or from about 354 g/cm to about 1181g/cm and/or from about 354 g/cm to about 984 g/cm and/or from about 394g/cm to about 787 g/cm.

The sanitary tissue products of the present invention may exhibit aninitial sum of MD and CD wet tensile strength of less than about 78 g/cmand/or less than about 59 g/cm and/or less than about 39 g/cm and/orless than about 29 g/cm.

The sanitary tissue products of the present invention may exhibit aninitial sum of MD and CD wet tensile strength of greater than about 118g/cm and/or greater than about 157 g/cm and/or greater than about 196g/cm and/or greater than about 236 g/cm and/or greater than about 276g/cm and/or greater than about 315 g/cm and/or greater than about 354g/cm and/or greater than about 394 g/cm and/or from about 118 g/cm toabout 1968 g/cm and/or from about 157 g/cm to about 1181 g/cm and/orfrom about 196 g/cm to about 984 g/cm and/or from about 196 g/cm toabout 787 g/cm and/or from about 196 g/cm to about 591 g/cm.

The sanitary tissue products of the present invention may exhibit adensity (based on measuring caliper at 95 g/in²) of less than about 0.60g/cm³ and/or less than about 0.30 g/cm³ and/or less than about 0.20g/cm³ and/or less than about 0.10 g/cm³ and/or less than about 0.07g/cm³ and/or less than about 0.05 g/cm³ and/or from about 0.01 g/cm³ toabout 0.20 g/cm³ and/or from about 0.02 g/cm³ to about 0.10 g/cm³.

The sanitary tissue products of the present invention may be in the formof sanitary tissue product rolls. Such sanitary tissue product rolls maycomprise a plurality of connected, but perforated sheets of fibrousstructure, that are separably dispensable from adjacent sheets.

In another example, the sanitary tissue products may be in the form ofdiscrete sheets that are stacked within and dispensed from a container,such as a box.

The fibrous structures and/or sanitary tissue products of the presentinvention may comprise additives such as surface softening agents, forexample silicones, quaternary ammonium compounds, aminosilicones,lotions, and mixtures thereof, temporary wet strength agents, permanentwet strength agents, bulk softening agents, wetting agents, latexes,especially surface-pattern-applied latexes, dry strength agents such ascarboxymethylcellulose and starch, and other types of additives suitablefor inclusion in and/or on sanitary tissue products.

“Fibrous structure” as used herein means a structure that comprises aplurality of pulp fibers. In one example, the fibrous structure maycomprise a plurality of wood pulp fibers. In another example, thefibrous structure may comprise a plurality of non-wood pulp fibers, forexample plant fibers, synthetic staple fibers, and mixtures thereof. Instill another example, in addition to pulp fibers, the fibrous structuremay comprise a plurality of filaments, such as polymeric filaments, forexample thermoplastic filaments such as polyolefin filaments (i.e.,polypropylene filaments) and/or hydroxyl polymer filaments, for examplepolyvinyl alcohol filaments and/or polysaccharide filaments such asstarch filaments. In one example, a fibrous structure according to thepresent invention means an orderly arrangement of fibers alone and withfilaments within a structure in order to perform a function.Non-limiting examples of fibrous structures of the present inventioninclude paper.

Non-limiting examples of processes for making fibrous structures includeknown wet-laid papermaking processes, for example conventionalwet-pressed papermaking processes and through-air-dried papermakingprocesses, and air-laid papermaking processes. Such processes typicallyinclude steps of preparing a fiber composition in the form of asuspension in a medium, either wet, more specifically aqueous medium, ordry, more specifically gaseous, i.e. with air as medium. The aqueousmedium used for wet-laid processes is oftentimes referred to as a fiberslurry. The fibrous slurry is then used to deposit a plurality of fibersonto a forming wire, fabric, or belt such that an embryonic fibrousstructure is formed, after which drying and/or bonding the fiberstogether results in a fibrous structure. Further processing the fibrousstructure may be carried out such that a finished fibrous structure isformed. For example, in typical papermaking processes, the finishedfibrous structure is the fibrous structure that is wound on the reel atthe end of papermaking, often referred to as a parent roll, and maysubsequently be converted into a finished product, e.g. a single- ormulti-ply sanitary tissue product.

The fibrous structures of the present invention may be homogeneous ormay be layered. If layered, the fibrous structures may comprise at leasttwo and/or at least three and/or at least four and/or at least fivelayers of fiber and/or filament compositions.

In one example, the fibrous structure of the present invention consistsessentially of fibers, for example pulp fibers, such as cellulosic pulpfibers and more particularly wood pulp fibers.

In another example, the fibrous structure of the present inventioncomprises fibers and is void of filaments.

In still another example, the fibrous structures of the presentinvention comprises filaments and fibers, such as a co-formed fibrousstructure.

“Co-formed fibrous structure” as used herein means that the fibrousstructure comprises a mixture of at least two different materialswherein at least one of the materials comprises a filament, such as apolypropylene filament, and at least one other material, different fromthe first material, comprises a solid additive, such as a fiber and/or aparticulate. In one example, a co-formed fibrous structure comprisessolid additives, such as fibers, such as wood pulp fibers, andfilaments, such as polypropylene filaments.

“Fiber” and/or “Filament” as used herein means an elongate particulatehaving an apparent length greatly exceeding its apparent width, i.e. alength to diameter ratio of at least about 10. In one example, a “fiber”is an elongate particulate as described above that exhibits a length ofless than 5.08 cm (2 in.) and a “filament” is an elongate particulate asdescribed above that exhibits a length of greater than or equal to 5.08cm (2 in.).

Fibers are typically considered discontinuous in nature. Non-limitingexamples of fibers include pulp fibers, such as wood pulp fibers, andsynthetic staple fibers such as polyester fibers.

Filaments are typically considered continuous or substantiallycontinuous in nature. Filaments are relatively longer than fibers.Non-limiting examples of filaments include meltblown and/or spunbondfilaments. Non-limiting examples of materials that can be spun intofilaments include natural polymers, such as starch, starch derivatives,cellulose and cellulose derivatives, hemicellulose, hemicellulosederivatives, and synthetic polymers including, but not limited topolyvinyl alcohol filaments and/or polyvinyl alcohol derivativefilaments, and thermoplastic polymer filaments, such as polyesters,nylons, polyolefins such as polypropylene filaments, polyethylenefilaments, and biodegradable or compostable thermoplastic fibers such aspolylactic acid filaments, polyhydroxyalkanoate filaments andpolycaprolactone filaments. The filaments may be monocomponent ormulticomponent, such as bicomponent filaments.

In one example of the present invention, “fiber” refers to papermakingfibers. Papermaking fibers useful in the present invention includecellulosic fibers commonly known as wood pulp fibers. Applicable woodpulps include chemical pulps, such as Kraft, sulfite, and sulfate pulps,as well as mechanical pulps including, for example, groundwood,thermomechanical pulp and chemically modified thermomechanical pulp.Chemical pulps, however, may be preferred since they impart a superiortactile sense of softness to tissue sheets made therefrom. Pulps derivedfrom both deciduous trees (hereinafter, also referred to as “hardwood”)and coniferous trees (hereinafter, also referred to as “softwood”) maybe utilized. The hardwood and softwood fibers can be blended, oralternatively, can be deposited in layers to provide a stratifiedfibrous structure. U.S. Pat. No. 4,300,981 and U.S. Pat. No. 3,994,771are incorporated herein by reference for the purpose of disclosinglayering of hardwood and softwood fibers. Also applicable to the presentinvention are fibers derived from recycled paper, which may contain anyor all of the above categories as well as other non-fibrous materialssuch as fillers and adhesives used to facilitate the originalpapermaking.

In one example, the wood pulp fibers are selected from the groupconsisting of hardwood pulp fibers, softwood pulp fibers, and mixturesthereof. The hardwood pulp fibers may be selected from the groupconsisting of: tropical hardwood pulp fibers, northern hardwood pulpfibers, and mixtures thereof. The tropical hardwood pulp fibers may beselected from the group consisting of: eucalyptus fibers, acacia fibers,and mixtures thereof. The northern hardwood pulp fibers may be selectedfrom the group consisting of: cedar fibers, maple fibers, and mixturesthereof.

In addition to the various wood pulp fibers, other cellulosic fiberssuch as cotton linters, rayon, lyocell, trichomes, seed hairs, andbagasse can be used in this invention. Other sources of cellulose in theform of fibers or capable of being spun into fibers include grasses andgrain sources.

“Trichome” or “trichome fiber” as used herein means an epidermalattachment of a varying shape, structure and/or function of a non-seedportion of a plant. In one example, a trichome is an outgrowth of theepidermis of a non-seed portion of a plant. The outgrowth may extendfrom an epidermal cell. In one embodiment, the outgrowth is a trichomefiber. The outgrowth may be a hairlike or bristlelike outgrowth from theepidermis of a plant.

Trichome fibers are different from seed hair fibers in that they are notattached to seed portions of a plant. For example, trichome fibers,unlike seed hair fibers, are not attached to a seed or a seed podepidermis. Cotton, kapok, milkweed, and coconut coir are non-limitingexamples of seed hair fibers.

Further, trichome fibers are different from nonwood bast and/or corefibers in that they are not attached to the bast, also known as phloem,or the core, also known as xylem portions of a nonwood dicotyledonousplant stem. Non-limiting examples of plants which have been used toyield nonwood bast fibers and/or nonwood core fibers include kenaf,jute, flax, ramie and hemp. Further trichome fibers are different frommonocotyledonous plant derived fibers such as those derived from cerealstraws (wheat, rye, barley, oat, etc), stalks (corn, cotton, sorghum,Hesperaloe funifera, etc.), canes (bamboo, bagasse, etc.), grasses(esparto, lemon, sabai, switchgrass, etc), since such monocotyledonousplant derived fibers are not attached to an epidermis of a plant.

Further, trichome fibers are different from leaf fibers in that they donot originate from within the leaf structure. Sisal and abaca aresometimes liberated as leaf fibers.

Finally, trichome fibers are different from wood pulp fibers since woodpulp fibers are not outgrowths from the epidermis of a plant; namely, atree. Wood pulp fibers rather originate from the secondary xylem portionof the tree stem.

“Basis Weight” as used herein is the weight per unit area of a samplereported in lbs/3000 ft² or g/m² (gsm) and is measured according to theBasis Weight Test Method described herein.

“Machine Direction” or “MD” as used herein means the direction parallelto the flow of the fibrous structure through the fibrous structuremaking machine and/or sanitary tissue product manufacturing equipment.

“Cross Machine Direction” or “CD” as used herein means the directionparallel to the width of the fibrous structure making machine and/orsanitary tissue product manufacturing equipment and perpendicular to themachine direction.

“Ply” as used herein means an individual, integral fibrous structure.

“Plies” as used herein means two or more individual, integral fibrousstructures disposed in a substantially contiguous, face-to-facerelationship with one another, forming a multi-ply fibrous structureand/or multi-ply sanitary tissue product. It is also contemplated thatan individual, integral fibrous structure can effectively form amulti-ply fibrous structure, for example, by being folded on itself

“Embossed” as used herein with respect to a fibrous structure and/orsanitary tissue product means that a fibrous structure and/or sanitarytissue product has been subjected to a process which converts a smoothsurfaced fibrous structure and/or sanitary tissue product to adecorative surface by replicating a design on one or more emboss rolls,which form a nip through which the fibrous structure and/or sanitarytissue product passes. Embossed does not include creping, microcreping,printing or other processes that may also impart a texture and/ordecorative pattern to a fibrous structure and/or sanitary tissueproduct.

“Differential density”, as used herein, means a fibrous structure and/orsanitary tissue product that comprises one or more regions of relativelylow fiber density, which are referred to as pillow regions, and one ormore regions of relatively high fiber density, which are referred to asknuckle regions.

“Densified”, as used herein means a portion of a fibrous structureand/or sanitary tissue product that is characterized by regions ofrelatively high fiber density (knuckle regions).

“Non-densified”, as used herein, means a portion of a fibrous structureand/or sanitary tissue product that exhibits a lesser density (one ormore regions of relatively lower fiber density) (pillow regions) thananother portion (for example a knuckle region) of the fibrous structureand/or sanitary tissue product.

“Non-rolled” as used herein with respect to a fibrous structure and/orsanitary tissue product of the present invention means that the fibrousstructure and/or sanitary tissue product is an individual sheet (forexample not connected to adjacent sheets by perforation lines. However,two or more individual sheets may be interleaved with one another) thatis not convolutedly wound about a core or itself. For example, anon-rolled product comprises a facial tissue.

“Stack Compressibility and Resilient Bulk Test Method” as used hereinmeans the Stack Compressibility and Resilient Bulk Test Method describedherein.

“Slip Stick Coefficient of Friction Test Method” as used herein meansthe Slip Stick Coefficient of Friction Test Method described herein.

“Plate Stiffness Test Method” as used herein means the Plate StiffnessTest Method described herein.

“Creped” as used herein means creped off of a Yankee dryer or othersimilar roll and/or fabric creped and/or belt creped. Rush transfer of afibrous structure alone does not result in a “creped” fibrous structureor “creped” sanitary tissue product for purposes of the presentinvention.

Sanitary Tissue Product

The sanitary tissue products of the present invention may be single-plyor multi-ply sanitary tissue products. In other words, the sanitarytissue products of the present invention may comprise one or morefibrous structures. The fibrous structures and/or sanitary tissueproducts of the present invention are made from a plurality of pulpfibers, for example wood pulp fibers and/or other cellulosic pulpfibers, for example trichomes. In addition to the pulp fibers, thefibrous structures and/or sanitary tissue products of the presentinvention may comprise synthetic fibers and/or filaments.

As shown in FIG. 1 and Table 1 below, which contains a portion of thedata values represented in FIG. 1, the sanitary tissue products of thepresent invention exhibit a combination of compressibility values asmeasured according to the Stack Compressibility and Resilient Bulk TestMethod, plate stiffness values as measured according to the PlateStiffness Test Method, slip stick coefficient of friction values asmeasured according to the Slip Stick Coefficient of Friction Test Methodand/or resilient bulk values as measured according to the StackCompressibility and Resilient Bulk Test Method that are novel over knownsanitary tissue products.

TABLE 1 Basis Plate Compressibility Resilient Weight Basis # ofSlipStick Stiffness 10-1250 Bulk (lbs/3000 Weight Sample plies COF*10k(N*mm) (-m) 5sht (cc/g) ft²) (gsm) Kroger Home Sense Soft 2 672 2.4835.55 44.39 32.17 52.36 & Strong Bath Kroger Home Sense 3 258 1.38 17.3136.91 27.25 44.35 Lotioned Facial Angle Soft ® 2 759 1.51 34.47 47.3025.07 40.80 Scott Extra Soft Tissue 1 725 2.27 45.64 72.40 19.20 31.25(UCTAD) Scott 1000 1 780 0.84 10.25 41.03 11.37 18.50 Cottonelle ® Ultra2 625 5.24 50.30 69.47 28.73 46.76 (UCTAD) Quilted Northern ® Ultra 3390 1.93 33.58 51.04 — — Plush Quilted Northern ® Ultra 2 510 3.33 25.6852.95 30.84 50.19 Soft & Strong Kirkland Extra Soft 2 382 2.76 21.9758.90 28.42 46.25 Kleenex ® Hand Towels 1 1016 4.36 44.10 56.20 40.6366.13 (DRC) NEVE Neuttro 2 528 1.37 18.66 55.15 19.33 31.46 NEVE Supreme3 428 2.65 18.72 53.20 28.82 46.90 Nepia Super Smooth 2 506 1.45 6.8142.69 22.74 37.01 Tempo Neutral 3 435 3.65 19.08 42.88 29.74 48.40Kleenex ® Tissue (Every 2 303 1.22 12.25 44.97 17.63 28.69 Day)Kleenex ® Tissue with 2 298 2.40 12.73 39.12 28.82 46.90 LotionKleenex ® Tissue Ultra 3 279 2.05 15.90 44.36 25.87 42.10 Soft Kleenex ®Tissue Cool 3 257 1.51 15.36 29.79 34.53 56.20 Touch Bounty ® Extra Soft2 743 9.19 54.98 65.66 36.32 59.11 Bounty ® Basic 1 1080 8.39 116.0295.76 24.71 40.22 Bounty ® 2 955 8.50 54.53 91.69 30.95 50.37 Brawny ® 21092 11.61 47.82 90.10 29.66 48.27 Charmin ® Ultra Soft 2 346 3.26 24.5155.13 31.13 50.66 Charmin ® Ultra Strong 2 437 3.97 30.21 76.03 22.9837.40 Charmin ® Premium 2 568 3.74 34.69 79.24 23.81 38.75 Puffs ® 2 3951.75 19.39 57.90 18.06 29.39 Puffs ® Plus 2 281 2.52 18.60 45.40 26.8743.73 Puffs ® Ultra 2 263 2.60 16.78 45.29 24.63 40.09 Scott Extra SoftTissue 1 992 2.86 43.28 73.72 19.20 31.25 (UCTAD) Members Mark 2 4402.96 24.92 70.15 23.31 37.94 Charmin ® Ultra Strong 2 535 4.18 35.0472.30 24.45 39.79 Cottonelle ® Ultra 2 690 5.29 47.30 68.66 27.71 45.10(UCTAD) Cottonelle ® Ultra 2 619 — 47.3 64.6 27.1 44.11 (UCTAD)Charmin ® Ultra Strong 2 437 3.97 30.21 76.03 22.98 37.40 Great ValueUltra Soft 2 366 2.55 28.8 63.3 24.5 39.87 Charmin ® Sensitive 2 4891.98 29.77 60.87 28.84 46.94 Charmin ® Basic 1 507 1.42 25.67 56.3120.03 32.60 Charmin ® Basic 1 565 1.26 23.36 58.98 18.89 30.74 Charmin ®Basic 1 534 1.58 24.54 58.94 18.67 30.39 Invention 2 670 2.98 50.8365.86 23.07 37.55 Invention 2 706 3.26 49.22 65.71 23.48 38.21 Invention2 768 4.65 61.99 75.86 27.36 44.53 Invention 2 389 2.79 47.81 53.8533.46 54.46 Invention 2 283 2.36 42.45 62.69 34.89 56.78 Invention 2 3403.75 33.80 57.00 30.12 49.02 Invention 2 371 2.79 36.66 57.77 31.0350.50 Invention 2 351 3.00 36.73 59.64 30.54 49.70 Invention 2 302 3.2644.39 62.61 30.66 49.90 Invention 2 318 2.45 35.95 64.50 31.69 51.58Invention 2 408 2.22 36.44 63.92 31.68 51.56 Invention 2 335 2.10 35.7462.56 31.42 51.14 Invention 2 264 2.92 27.79 60.88 29.98 48.79 Invention2 260 3.90 27.62 65.95 29.22 47.56 Invention 2 230 3.04 24.56 64.0431.14 50.68 Invention 2 256 3.79 27.08 65.30 — — Invention-Example 4 2253 3.24 30.65 66.06 — — Invention 2 269 4.42 29.86 62.05 — — Invention2 445 2.81 42.65 56.74 30.28 49.28 Invention 2 262 2.62 36.15 58.6732.37 52.68 Invention 2 246 2.60 36.40 54.83 34.45 56.07 Invention 2 3922.49 40.83 54.95 29.95 48.74 Invention 2 445 2.81 42.65 56.74 30.2849.28 Invention 2 311 3.31 33.01 55.34 27.69 45.07 Invention 2 333 2.9234.45 57.58 30.49 49.62 Invention 2 321 2.16 35.00 64.47 29.81 48.52Invention 2 393 2.38 43.09 57.58 31.08 50.58 Invention 2 287 2.49 36.9955.72 31.66 51.53 Invention-Example 5 2 732 1.36 43.10 63.80 21.26 34.60Invention-Example 6 2 745 1.90 56.30 84.70 20.70 33.69 Invention 2 6432.68 52.30 70.20 26.99 43.93 Invention 2 438 2.82 33.42 67.75 30.3049.31 Invention 2 511 3.77 55.20 68.05 33.80 55.01 Invention-Example 7 2708 11.51 68.4 100.4 31.5 51.27 Invention 2 675 11.64 66.8 94.7 33.053.71

In one example of the present invention, the sanitary tissue product ofthe present invention exhibits a Compressibility of greater than 46and/or greater than 47 and/or greater than 49 and/or greater than 50mils/(log(g/in²)) as measured according to the Stack Compressibility andResilient Bulk Test Method and a Plate Stiffness of less than 5.2 and/orless than 5 and/or less than 4.75 and/or less than 4 and/or less than3.5 and/or less than 3 and/or less than 2.5 N*mm as measured accordingto the Plate Stiffness Test Method.

In another example of the present invention, the sanitary tissue productof the present invention is a 3D patterned sanitary tissue productcomprising at least one 3D patterned fibrous structure ply, wherein thesanitary tissue product exhibits a Compressibility of greater than 46and/or greater than 47 and/or greater than 49 and/or greater than 50mils/(log(g/in²)) as measured according to the Stack Compressibility andResilient Bulk Test Method and a Plate Stiffness of less than 5.2 and/orless than 5 and/or less than 4.75 and/or less than 4 and/or less than3.5 and/or less than 3 and/or less than 2.5 N*mm as measured accordingto the Plate Stiffness Test Method.

In another example of the present invention, a sanitary tissue productof the present invention, for example a bath tissue product, comprisesat least one creped through-air-dried fibrous structure ply comprising aplurality of pulp fibers, wherein the sanitary tissue product exhibits aCompressibility of greater than 36 and/or greater than 38 and/or greaterthan 40 and/or greater than 42 and/or greater than 46 and/or greaterthan 47 and/or greater than 49 and/or greater than 50 mils/(log(g/in²))as measured according to the Stack Compressibility and Resilient BulkTest Method and a Plate Stiffness of less than 5.2 and/or less than 5and/or less than 4.75 and/or less than 4 and/or less than 3.5 and/orless than 3 and/or less than 2.5 N*mm as measured according to the PlateStiffness Test Method.

In even another example of the present invention, the sanitary tissueproduct is a multi-ply, for example two-ply, sanitary tissue product,for example bath tissue product, that exhibits a Compressibility ofgreater than 36 and/or greater than 38 and/or greater than 40 and/orgreater than 42 and/or greater than 46 and/or greater than 47 and/orgreater than 49 and/or greater than 50 mils/(log(g/in²)) as measuredaccording to the Stack Compressibility and Resilient Bulk Test Methodand a Plate Stiffness of less than 5.2 and/or less than 5 and/or lessthan 4.75 and/or less than 4 and/or less than 3.5 and/or less than 3and/or less than 2.5 N*mm as measured according to the Plate StiffnessTest Method.

In even yet another example of the present invention, the sanitarytissue product is a multi-ply, for example two-ply, sanitary tissueproduct, for example bath tissue product, comprising at least one 3Dpatterned fibrous structure ply, for example a 3D patternedthrough-air-dried fibrous structure ply, wherein the sanitary tissueproduct exhibits a Compressibility of greater than 36 and/or greaterthan 38 and/or greater than 40 and/or greater than 42 and/or greaterthan 46 and/or greater than 47 and/or greater than 49 and/or greaterthan 50 mils/(log(g/in²)) as measured according to the StackCompressibility and Resilient Bulk Test Method and a Plate Stiffness ofless than 5.2 and/or less than 5 and/or less than 4.75 and/or less than4 and/or less than 3.5 and/or less than 3 and/or less than 2.5 N*mm asmeasured according to the Plate Stiffness Test Method.

In one example, a sanitary tissue product of the present invention is amulti-ply sanitary tissue product comprising at least onethrough-air-dried fibrous structure comprising a plurality of pulpfibers, wherein the multi-ply sanitary tissue product exhibits acompressibility of greater than 36 and/or greater than 38 and/or greaterthan 40 and/or greater than 46 mils/(log(g/in²)) as measured accordingto the Stack Compressibility and Resilient Bulk Test Method and a platestiffness of less than 5 and/or less than 4.75 and/or less than 4 and/orless than 3.5 and/or less than 3 and/or less than 2.5 N*mm as measuredaccording to the Plate Stiffness Test Method.

In another example, a sanitary tissue product of the present inventionis a multi-ply sanitary tissue product comprising at least one creped,through-air-dried fibrous structure comprising a plurality of pulpfibers, wherein the multi-ply sanitary tissue product exhibits acompressibility of greater than 36 and/or greater than 38 and/or greaterthan 40 and/or greater than 46 mils/(log(g/in²)) as measured accordingto the Stack Compressibility and Resilient Bulk Test Method and a platestiffness of less than 8.3 and/or less than 7 and/or less than 5 and/orless than 4.75 and/or less than 4 and/or less than 3.5 and/or less than3 and/or less than 2.5 N*mm as measured according to the Plate StiffnessTest Method.

In another example of the present invention, in addition to exhibitingthe Compressibility as described above, the sanitary tissue product ofthe present invention may also exhibit a Slip Stick Coefficient ofFriction of less than 725 and/or less than 700 and/or less than 625and/or less than 620 and/or less than 500 and/or less than 340 and/orless than 314 and/or less than 312 and/or less than 300 and/or less than290 and/or less than 280 and/or less than 275 and/or less than 260(COF*10000) as measured according to the Slip Stick Coefficient ofFriction Test Method.

In another example of the present invention, a multi-ply bath tissueproduct, for example a bath tissue product that exhibits a sum of MD andCD dry tensile of less than 1000 g/in, comprises at least one crepedthrough-air-dried fibrous structure ply comprising a plurality of pulpfibers, wherein the sanitary tissue product exhibits a Compressibilityof greater than 36 and/or greater than 38 and/or greater than 40 and/orgreater than 42 and/or greater than 46 and/or greater than 47 and/orgreater than 49 and/or greater than 50 mils/(log(g/in²)) as measuredaccording to the Stack Compressibility and Resilient Bulk Test Method.

In another example of the present invention, the sanitary tissue productof the present invention exhibits a Plate Stiffness of less than 8.3and/or less than 8 and/or less than 6 and/or less than 5 and/or lessthan 3 and/or less than 2 and/or greater than 0 and/or greater than 0.5and/or greater than 1 and/or greater than 1.25 and/or greater than 1.5and/or greater than 1.75 N*mm as measured according to the PlateStiffness Test Method and a Resilient Bulk of greater than 80 and/orgreater than 82 and/or greater than 84 cc/g as measured according to theStack Compressibility and Resilient Bulk Test Method.

In another example of the present invention, the sanitary tissue productof the present invention is a multi-ply sanitary tissue product and/orcomprises a creped fibrous structure that exhibits a Plate Stiffness ofless than 2.9 and/or less than 2.75 and/or less than 2.25 and/or lessthan 2 and/or greater than 0 and/or greater than 0.5 and/or greater than1 and/or greater than 1.25 and/or greater than 1.5 and/or greater than1.75 N*mm as measured according to the Plate Stiffness Test Method and aResilient Bulk of greater than 64 and/or greater than 70 and/or greaterthan 75 and/or greater than 80 and/or greater than 82 and/or greaterthan 84 cc/g as measured according to the Stack Compressibility andResilient Bulk Test Method.

In another example of the present invention, the sanitary tissue productof the present invention is a multi-ply sanitary tissue product thatexhibits a Plate Stiffness of less than 1.6 and/or less than 1.5 and/orless than 1.4 and/or greater than 0 and/or greater than 0.5 and/orgreater than 1 and/or greater than 1.2 N*mm as measured according to thePlate Stiffness Test Method and a Resilient Bulk of greater than 56and/or greater than 60 and/or greater than 64 and/or greater than 70and/or greater than 75 and/or greater than 80 and/or greater than 82and/or greater than 84 cc/g as measured according to the StackCompressibility and Resilient Bulk Test Method.

In another example of the present invention, the sanitary tissue productof the present invention exhibits a Plate Stiffness of less than 2.2and/or less than 2.1 and/or less than 2 and/or greater than 0 and/orgreater than 0.5 and/or greater than 1 and/or greater than 1.2 and/orgreater than 1.4 and/or greater than 1.6 and/or greater than 1.75 N*mmas measured according to the Plate Stiffness Test Method, a ResilientBulk of greater than 56 and/or greater than 60 and/or greater than 64and/or greater than 70 and/or greater than 75 and/or greater than 80and/or greater than 82 and/or greater than 84 cc/g as measured accordingto the Stack Compressibility and Resilient Bulk Test Method, and aCompressibility of greater than 34.5 and/or greater than 37 and/orgreater than 40 and/or greater than 42 and/or greater than 45 and/orgreater than 50 and/or greater than 55 mils/(log(g/in²)) as measuredaccording to the Stack Compressibility and Resilient Bulk Test Method.

In another example of the present invention, the sanitary tissue productof the present invention exhibits a Plate Stiffness of less than 8.3and/or less than 8 and/or less than 6 and/or less than 5 and/or lessthan 3 and/or less than 2 and/or greater than 0 and/or greater than 0.5and/or greater than 1 and/or greater than 1.25 and/or greater than 1.5and/or greater than 1.75 N*mm as measured according to the PlateStiffness Test Method, a Resilient Bulk of greater than 80 and/orgreater than 82 and/or greater than 84 cc/g as measured according to theStack Compressibility and Resilient Bulk Test Method, and aCompressibility of greater than 30 and/or greater than 32 and/or greaterthan 34.5 and/or greater than 37 and/or greater than 40 and/or greaterthan 42 and/or greater than 45 and/or greater than 50 and/or greaterthan 55 mils/(log(g/in²)) as measured according to the StackCompressibility and Resilient Bulk Test Method.

In another example of the present invention, the sanitary tissue productof the present invention exhibits a Plate Stiffness of less than 2.2and/or less than 2.1 and/or less than 2 and/or greater than 0 and/orgreater than 0.5 and/or greater than 1 and/or greater than 1.2 and/orgreater than 1.4 and/or greater than 1.6 and/or greater than 1.75 N*mmas measured according to the Plate Stiffness Test Method, aCompressibility of greater than 33 and/or greater than 34.5 and/orgreater than 37 and/or greater than 40 and/or greater than 42 and/orgreater than 45 and/or greater than 50 and/or greater than 55mils/(log(g/in²)) as measured according to the Stack Compressibility andResilient Bulk Test Method, and a Basis Weight of less than 25 and/orless than 24 and/or less than 23 and/or less than 22 and/or less than21.5 and/or less than 21 and/or greater than 0 and/or greater than 10and/or greater than 15 lbs/3000 ft² as measured according to the BasisWeight Test Method.

In another example of the present invention, the sanitary tissue productof the present invention exhibits a Compressibility of greater than 45and/or greater than 45.6 and/or greater than 50 and/or greater than 55mils/(log(g/in²)) as measured according to the Stack Compressibility andResilient Bulk Test Method and a Basis Weight of less than 25 and/orless than 24.7 and/or less than 24 and/or less than 23 and/or less than22 and/or less than 21.5 and/or less than 21 and/or greater than 0and/or greater than 10 and/or greater than 15 lbs/3000 ft² as measuredaccording to the Basis Weight Test Method.

In another example of the present invention, the sanitary tissue productof the present invention is a multi-ply sanitary tissue product thatexhibits a Compressibility of greater than 0 and/or greater than 10and/or greater than 15 and/or greater than 20 mils/(log(g/in²)) asmeasured according to the Stack Compressibility and Resilient Bulk TestMethod and a Basis Weight of less than 23 and/or less than 22.9 and/orless than 22 and/or less than 21.5 and/or less than 21 and/or greaterthan 0 and/or greater than 10 and/or greater than 15 lbs/3000 ft² asmeasured according to the Basis Weight Test Method.

In another example of the present invention, the sanitary tissue productof the present invention comprises a creped fibrous structure such thatthe sanitary tissue product exhibits a Compressibility of greater than32 and/or greater than 32.25 and/or greater than 33 and/or greater than34.5 and/or greater than 37 and/or greater than 40 and/or greater than42 and/or greater than 45 and/or greater than 50 and/or greater than 55mils/(log(g/in²)) as measured according to the Stack Compressibility andResilient Bulk Test Method and a Basis Weight of less than 23 and/orless than 22.9 and/or less than 22 and/or less than 21.5 and/or lessthan 21 and/or greater than 0 and/or greater than 10 and/or greater than15 lbs/3000 ft² as measured according to the Basis Weight Test Method.

In another example of the present invention, the sanitary tissue productof the present invention comprises a creped fibrous structure such thatthe sanitary tissue product exhibits a Compressibility of greater than36 and/or greater than 37 and/or greater than 40 and/or greater than 42and/or greater than 45 and/or greater than 50 and/or greater than 55and/or less than 115 and/or less than 100 and/or less than 90mils/(log(g/in²)) as measured according to the Stack Compressibility andResilient Bulk Test Method and a Basis Weight of less than 29.6 and/orless than 29 and/or less than 28 and/or less than 27 and/or less than 25and/or less than 24 and/or less than 23 and/or less than 22.9 and/orless than 22 and/or less than 21.5 and/or less than 21 and/or greaterthan 0 and/or greater than 10 and/or greater than 15 lbs/3000 ft² asmeasured according to the Basis Weight Test Method.

In another example of the present invention, the sanitary tissue productof the present invention exhibits a Slip Stick Coefficient of Frictionof less than 950 and/or less than 900 and/or less than 850 and/or lessthan 800 and/or less than 775 and/or less than 725 and/or less than 700and/or less than 625 and/or less than 620 and/or less than 500 and/orless than 340 and/or less than 314 and/or less than 312 and/or less than300 and/or less than 290 and/or less than 280 and/or less than 275and/or less than 260 (COF*10000) as measured according to the Slip StickCoefficient of Friction Test Method and a Resilient Bulk of greater than80 and/or greater than 82 and/or greater than 84 cc/g as measuredaccording to the Stack Compressibility and Resilient Bulk Test Method.

In another example of the present invention, the sanitary tissue productof the present invention exhibits a Slip Stick Coefficient of Frictionof less than 300 and/or less than 290 and/or less than 280 and/or lessthan 275 and/or less than 260 (COF*10000) as measured according to theSlip Stick Coefficient of Friction Test Method and a Resilient Bulk ofgreater than 55 and/or greater than 56 and/or greater than 60 and/orgreater than 64 and/or greater than 70 and/or greater than 75 and/orgreater than 80 and/or greater than 82 and/or greater than 84 cc/g asmeasured according to the Stack Compressibility and Resilient Bulk TestMethod.

The fibrous structures and/or sanitary tissue products of the presentinvention may be creped or uncreped.

The fibrous structures and/or sanitary tissue products of the presentinvention may be wet-laid or air-laid.

The fibrous structures and/or sanitary tissue products of the presentinvention may be embossed.

The fibrous structures and/or sanitary tissue products of the presentinvention may comprise a surface softening agent or be void of a surfacesoftening agent. In one example, the sanitary tissue product is anon-lotioned sanitary tissue product, such as a sanitary tissue productcomprising a non-lotioned fibrous structure ply, for example anon-lotioned through-air-dried fibrous structure ply, for example anon-lotioned creped through-air-dried fibrous structure ply and/or anon-lotioned uncreped through-air-dried fibrous structure ply. In yetanother example, the sanitary tissue product may comprise a non-lotionedfabric creped fibrous structure ply and/or a non-lotioned belt crepedfibrous structure ply.

The fibrous structures and/or sanitary tissue products of the presentinvention may comprise trichome fibers and/or may be void of trichomefibers.

The fibrous structures and/or sanitary tissue products of the presentinvention may exhibit the compressibility values alone or in combinationwith the plate stiffness values with or without the aid of surfacesoftening agents. In other words, the sanitary tissue products of thepresent invention may exhibit the compressibility values described abovealone or in combination with the plate stiffness values when surfacesoftening agents are not present on and/or in the sanitary tissueproducts, in other words the sanitary tissue product is void of surfacesoftening agents. This does not mean that the sanitary tissue productsthemselves cannot include surface softening agents. It simply means thatwhen the sanitary tissue product is made without adding the surfacesoftening agents, the sanitary tissue product exhibits thecompressibility and plate stiffness values of the present invention.Addition of a surface softening agent to such a sanitary tissue productwithin the scope of the present invention (without the need of a surfacesoftening agent or other chemistry) may enhance the sanitary tissueproduct's compressibility and/or plate stiffness to an extent. However,sanitary tissue products that need the inclusion of surface softeningagents on and/or in them to be within the scope of the presentinvention, in other words to achieve the compressibility and platestiffness values of the present invention, are outside the scope of thepresent invention.

Patterned Molding Members

The sanitary tissue products of the present invention and/or fibrousstructure plies employed in the sanitary tissue products of the presentinvention are formed on patterned molding members that result in thesanitary tissue products of the present invention. In one example, thepattern molding member comprises a non-random repeating pattern. Inanother example, the pattern molding member comprises a resinouspattern.

A “reinforcing element” may be a desirable (but not necessary) elementin some examples of the molding member, serving primarily to provide orfacilitate integrity, stability, and durability of the molding membercomprising, for example, a resinous material. The reinforcing elementcan be fluid-permeable or partially fluid-permeable, may have a varietyof embodiments and weave patterns, and may comprise a variety ofmaterials, such as, for example, a plurality of interwoven yarns(including Jacquard-type and the like woven patterns), a felt, aplastic, other suitable synthetic material, or any combination thereof.

As shown in FIGS. 2A and 2B, a non-limiting of a patterned moldingmember suitable for use in the present invention comprises athrough-air-drying belt 10. The through-air-drying belt 10 comprises aplurality of discrete knuckles 12 formed by line segments of resin 14arranged in a non-random, repeating pattern, such as a woven pattern,for example a herringbone pattern. The discrete knuckles 12 aredispersed within a continuous pillow network 16, which constitute adeflection conduit into which portions of a fibrous structure ply beingmade on the through-air-drying belt 10 of FIGS. 2A and 2B deflect. FIG.3 is a MikroCAD image of a resulting sanitary tissue product 18 beingmade on the through-air-drying belt 10. The sanitary tissue product 18comprises a continuous pillow region 20 imparted by the continuouspillow network 16 of the through-air-drying belt 10 of FIGS. 2A and 2B.The sanitary tissue product 18 further comprises discrete knuckleregions 22 imparted by the discrete knuckles 12 of thethrough-air-drying belt 10 of FIGS. 2A and 2B. The continuous pillowregion 20 and discrete knuckle regions 22 may exhibit differentdensities, for example, one or more of the discrete knuckle regions 22may exhibit a density that is greater than the density of the continuouspillow region 20.

As shown in FIGS. 4A-4C, a non-limiting example of another patternedmolding member suitable for use in the present invention comprises athrough-air-drying belt 10. The through-air-drying belt 10 comprises aplurality of semi-continuous knuckles 24 formed by semi-continuous linesegments of resin 26 arranged in a non-random, repeating pattern, forexample a substantially cross-machine direction repeating pattern ofsemi-continuous lines supported on a support fabric comprising filaments27. In this case, the semi-continuous lines are curvilinear, for examplesinusoidal. The semi-continuous knuckles 24 are spaced from adjacentsemi-continuous knuckles 24 by semi-continuous pillows 28, whichconstitute deflection conduits into which portions of a fibrousstructure ply being made on the through-air-drying belt 10 of FIGS.4A-4C deflect. As shown in FIGS. 5A-5D, a resulting sanitary tissueproduct 18 being made on the through-air-drying belt 10 of FIGS. 4A-4Ccomprises semi-continuous pillow regions 30 imparted by thesemi-continuous pillows 28 of the through-air-drying belt 10 of FIGS.4A-4C. The sanitary tissue product 18 further comprises semi-continuousknuckle regions 32 imparted by the semi-continuous knuckles 24 of thethrough-air-drying belt 10 of FIGS. 4A-4C. The semi-continuous pillowregions 30 and semi-continuous knuckle regions 32 may exhibit differentdensities, for example, one or more of the semi-continuous knuckleregions 32 may exhibit a density that is greater than the density of oneor more of the semi-continuous pillow regions 30.

Without wishing to be bound by theory, foreshortening (dry & wet crepe,fabric crepe, rush transfer, etc) is an integral part of fibrousstructure and/or sanitary tissue paper making, helping to produce thedesired balance of strength, stretch, softness, absorbency, etc. Fibrousstructure support, transport and molding members used in the papermakingprocess, such as rolls, wires, felts, fabrics, belts, etc. have beenvariously engineered to interact with foreshortening to further controlthe fibrous structure and/or sanitary tissue product properties. In thepast, it has been thought that it is advantageous to avoid highly CDdominant knuckle designs that result in MD oscillations offoreshortening forces. However, it has unexpectedly been found that themolding member of FIGS. 4A-4C provides patterned molding member havingCD dominant semi-continuous knuckles that to enable better control ofthe fibrous structure's molding and stretch while overcoming thenegatives of the past.

As shown in FIGS. 6A-6C, a non-limiting example of another patternedmolding member suitable for use in the present invention comprises athrough-air-drying belt 10. The through-air-drying belt 10 comprises aplurality of semi-continuous knuckles 24 formed by semi-continuous linesegments of resin 26 arranged in a non-random, repeating pattern, forexample a substantially machine direction repeating pattern ofsemi-continuous lines supported on a support fabric comprising filaments27. In this case, unlike in FIGS. 4A-4C, the semi-continuous lines aresubstantially straight, they are not curvilinear. The semi-continuousknuckles 24 are spaced from adjacent semi-continuous knuckles 24 bysemi-continuous pillows 28, which constitute deflection conduits intowhich portions of a fibrous structure ply being made on thethrough-air-drying belt 10 of FIGS. 6A-6C deflect. In addition to thesemi-continuous line segments of resin 26, the through-air-drying belt10 further comprises a plurality of discrete knuckles 12 formed bydiscrete line segments 14 which overlay one or more of thesemi-continuous knuckles 24. The arrangement of the discrete knuckles 12creates discrete pillows 34. In one case, this through-air-drying belt10 is referred to as a dual cast through-air-drying belt, which meansthat the semi-continuous knuckles 24 are formed first and then thediscrete knuckles 12 are formed such that they overlay one or more ofthe semi-continuous knuckles 24 and a multi-elevational belt and patternon the resulting sanitary tissue product are formed. As shown in FIGS.7A and 7B, a resulting sanitary tissue product 18 being made on thethrough-air-drying belt 10 of FIGS. 6A-6C comprises semi-continuouspillow regions 30 at a first elevation (the lowest elevation) impartedby the semi-continuous pillows 28 of the through-air-drying belt 10 ofFIGS. 6A-6C. The sanitary tissue product 18 further comprisessemi-continuous knuckle regions 32 imparted by the semi-continuousknuckles 24 of the through-air-drying belt 10 of FIGS. 6A-6C. Inaddition, the sanitary tissue product 18 further comprises discretepillow regions 34 The semi-continuous pillow regions 30 andsemi-continuous knuckle regions 32 may exhibit different densities, forexample, one or more of the semi-continuous knuckle regions 32 mayexhibit a density that is greater than the density of one or more of thesemi-continuous pillow regions 30.

Non-Limiting Examples of Making Sanitary Tissue Products

The sanitary tissue products of the present invention may be made by anysuitable papermaking process so long as a molding member of the presentinvention is used to making the sanitary tissue product or at least onefibrous structure ply of the sanitary tissue product and that thesanitary tissue product exhibits a compressibility and plate stiffnessvalues of the present invention. The method may be a sanitary tissueproduct making process that uses a cylindrical dryer such as a Yankee (aYankee-process) or it may be a Yankeeless process as is used to makesubstantially uniform density and/or uncreped fibrous structures and/orsanitary tissue products. Alternatively, the fibrous structures and/orsanitary tissue products may be made by an air-laid process and/ormeltblown and/or spunbond processes and any combinations thereof so longas the fibrous structures and/or sanitary tissue products of the presentinvention are made thereby.

As shown in FIG. 8, one example of a process and equipment, representedas 36 for making a sanitary tissue product according to the presentinvention comprises supplying an aqueous dispersion of fibers (a fibrousfurnish or fiber slurry) to a headbox 38 which can be of any convenientdesign. From headbox 38 the aqueous dispersion of fibers is delivered toa first foraminous member 40 which is typically a Fourdrinier wire, toproduce an embryonic fibrous structure 42.

The first foraminous member 40 may be supported by a breast roll 44 anda plurality of return rolls 46 of which only two are shown. The firstforaminous member 40 can be propelled in the direction indicated bydirectional arrow 48 by a drive means, not shown. Optional auxiliaryunits and/or devices commonly associated fibrous structure makingmachines and with the first foraminous member 40, but not shown, includeforming boards, hydrofoils, vacuum boxes, tension rolls, support rolls,wire cleaning showers, and the like.

After the aqueous dispersion of fibers is deposited onto the firstforaminous member 40, embryonic fibrous structure 42 is formed,typically by the removal of a portion of the aqueous dispersing mediumby techniques well known to those skilled in the art. Vacuum boxes,forming boards, hydrofoils, and the like are useful in effecting waterremoval. The embryonic fibrous structure 42 may travel with the firstforaminous member 40 about return roll 46 and is brought into contactwith a patterned molding member 50, such as a 3D patternedthrough-air-drying belt. While in contact with the patterned moldingmember 50, the embryonic fibrous structure 42 will be deflected,rearranged, and/or further dewatered.

The patterned molding member 50 may be in the form of an endless belt.In this simplified representation, the patterned molding member 50passes around and about patterned molding member return rolls 52 andimpression nip roll 54 and may travel in the direction indicated bydirectional arrow 56. Associated with patterned molding member 50, butnot shown, may be various support rolls, other return rolls, cleaningmeans, drive means, and the like well known to those skilled in the artthat may be commonly used in fibrous structure making machines.

After the embryonic fibrous structure 42 has been associated with thepatterned molding member 50, fibers within the embryonic fibrousstructure 42 are deflected into pillows and/or pillow network(“deflection conduits”) present in the patterned molding member 50. Inone example of this process step, there is essentially no water removalfrom the embryonic fibrous structure 42 through the deflection conduitsafter the embryonic fibrous structure 42 has been associated with thepatterned molding member 50 but prior to the deflecting of the fibersinto the deflection conduits. Further water removal from the embryonicfibrous structure 42 can occur during and/or after the time the fibersare being deflected into the deflection conduits. Water removal from theembryonic fibrous structure 42 may continue until the consistency of theembryonic fibrous structure 42 associated with patterned molding member50 is increased to from about 25% to about 35%. Once this consistency ofthe embryonic fibrous structure 42 is achieved, then the embryonicfibrous structure 42 can be referred to as an intermediate fibrousstructure 58. During the process of forming the embryonic fibrousstructure 42, sufficient water may be removed, such as by anoncompressive process, from the embryonic fibrous structure 42 beforeit becomes associated with the patterned molding member 50 so that theconsistency of the embryonic fibrous structure 42 may be from about 10%to about 30%.

While applicants decline to be bound by any particular theory ofoperation, it appears that the deflection of the fibers in the embryonicfibrous structure and water removal from the embryonic fibrous structurebegin essentially simultaneously. Embodiments can, however, beenvisioned wherein deflection and water removal are sequentialoperations. Under the influence of the applied differential fluidpressure, for example, the fibers may be deflected into the deflectionconduit with an attendant rearrangement of the fibers. Water removal mayoccur with a continued rearrangement of fibers. Deflection of thefibers, and of the embryonic fibrous structure, may cause an apparentincrease in surface area of the embryonic fibrous structure. Further,the rearrangement of fibers may appear to cause a rearrangement in thespaces or capillaries existing between and/or among fibers.

It is believed that the rearrangement of the fibers can take one of twomodes dependent on a number of factors such as, for example, fiberlength. The free ends of longer fibers can be merely bent in the spacedefined by the deflection conduit while the opposite ends are restrainedin the region of the ridges. Shorter fibers, on the other hand, canactually be transported from the region of the ridges into thedeflection conduit (The fibers in the deflection conduits will also berearranged relative to one another). Naturally, it is possible for bothmodes of rearrangement to occur simultaneously.

As noted, water removal occurs both during and after deflection; thiswater removal may result in a decrease in fiber mobility in theembryonic fibrous structure. This decrease in fiber mobility may tend tofix and/or freeze the fibers in place after they have been deflected andrearranged. Of course, the drying of the fibrous structure in a laterstep in the process of this invention serves to more firmly fix and/orfreeze the fibers in position.

Any convenient means conventionally known in the papermaking art can beused to dry the intermediate fibrous structure 58. Examples of suchsuitable drying process include subjecting the intermediate fibrousstructure 58 to conventional and/or flow-through dryers and/or Yankeedryers.

In one example of a drying process, the intermediate fibrous structure58 in association with the patterned molding member 50 passes around thepatterned molding member return roll 52 and travels in the directionindicated by directional arrow 56. The intermediate fibrous structure 58may first pass through an optional predryer 60. This predryer 60 can bea conventional flow-through dryer (hot air dryer) well known to thoseskilled in the art. Optionally, the predryer 60 can be a so-calledcapillary dewatering apparatus. In such an apparatus, the intermediatefibrous structure 58 passes over a sector of a cylinder havingpreferential-capillary-size pores through its cylindrical-shaped porouscover. Optionally, the predryer 60 can be a combination capillarydewatering apparatus and flow-through dryer. The quantity of waterremoved in the predryer 60 may be controlled so that a predried fibrousstructure 62 exiting the predryer 60 has a consistency of from about 30%to about 98%. The predried fibrous structure 62, which may still beassociated with patterned molding member 50, may pass around anotherpatterned molding member return roll 52 and as it travels to animpression nip roll 54. As the predried fibrous structure 62 passesthrough the nip formed between impression nip roll 54 and a surface of aYankee dryer 64, the pattern formed by the top surface 66 of patternedmolding member 50 is impressed into the predried fibrous structure 62 toform a 3D patterned fibrous structure 68. The imprinted fibrousstructure 68 can then be adhered to the surface of the Yankee dryer 64where it can be dried to a consistency of at least about 95%.

The 3D patterned fibrous structure 68 can then be foreshortened bycreping the 3D patterned fibrous structure 68 with a creping blade 70 toremove the 3D patterned fibrous structure 68 from the surface of theYankee dryer 64 resulting in the production of a 3D patterned crepedfibrous structure 72 in accordance with the present invention. As usedherein, foreshortening refers to the reduction in length of a dry(having a consistency of at least about 90% and/or at least about 95%)fibrous structure which occurs when energy is applied to the dry fibrousstructure in such a way that the length of the fibrous structure isreduced and the fibers in the fibrous structure are rearranged with anaccompanying disruption of fiber-fiber bonds. Foreshortening can beaccomplished in any of several well-known ways. One common method offoreshortening is creping. The 3D patterned creped fibrous structure 72may be subjected to post processing steps such as calendaring, tuftgenerating operations, and/or embossing and/or converting.

Another example of a suitable papermaking process for making thesanitary tissue products of the present invention is illustrated in FIG.9. FIG. 9 illustrates an uncreped through-air-drying process. In thisexample, a multi-layered headbox 74 deposits an aqueous suspension ofpapermaking fibers between forming wires 76 and 78 to form an embryonicfibrous structure 80. The embryonic fibrous structure 80 is transferredto a slower moving transfer fabric 82 with the aid of at least onevacuum box 84. The level of vacuum used for the fibrous structuretransfers can be from about 3 to about 15 inches of mercury (76 to about381 millimeters of mercury). The vacuum box 84 (negative pressure) canbe supplemented or replaced by the use of positive pressure from theopposite side of the embryonic fibrous structure 80 to blow theembryonic fibrous structure 80 onto the next fabric in addition to or asa replacement for sucking it onto the next fabric with vacuum. Also, avacuum roll or rolls can be used to replace the vacuum box(es) 84.

The embryonic fibrous structure 80 is then transferred to a moldingmember 50 of the present invention, such as a through-air-drying fabric,and passed over through-air-dryers 86 and 88 to dry the embryonicfibrous structure 80 to form a 3D patterned fibrous structure 90. Whilesupported by the molding member 50, the 3D patterned fibrous structure90 is finally dried to a consistency of about 94% percent or greater.After drying, the 3D patterned fibrous structure 90 is transferred fromthe molding member 50 to fabric 92 and thereafter briefly sandwichedbetween fabrics 92 and 94. The dried 3D patterned fibrous structure 90remains with fabric 94 until it is wound up at the reel 96 (“parentroll”) as a finished fibrous structure. Thereafter, the finished 3Dpatterned fibrous structure 90 can be unwound, calendered and convertedinto the sanitary tissue product of the present invention, such as aroll of bath tissue, in any suitable manner.

Yet another example of a suitable papermaking process for making thesanitary tissue products of the present invention is illustrated in FIG.10. FIG. 10 illustrates a papermaking machine 98 having a conventionaltwin wire forming section 100, a felt run section 102, a shoe presssection 104, a molding member section 106, in this case a creping fabricsection, and a Yankee dryer section 108 suitable for practicing thepresent invention. Forming section 100 includes a pair of formingfabrics 110 and 112 supported by a plurality of rolls 114 and a formingroll 116. A headbox 118 provides papermaking furnish to a nip 120between forming roll 116 and roll 114 and the fabrics 110 and 112. Thefurnish forms an embryonic fibrous structure 122 which is dewatered onthe fabrics 110 and 112 with the assistance of vacuum, for example, byway of vacuum box 124.

The embryonic fibrous structure 122 is advanced to a papermaking felt126 which is supported by a plurality of rolls 114 and the felt 126 isin contact with a shoe press roll 128. The embryonic fibrous structure122 is of low consistency as it is transferred to the felt 126. Transfermay be assisted by vacuum; such as by a vacuum roll if so desired or apickup or vacuum shoe as is known in the art. As the embryonic fibrousstructure 122 reaches the shoe press roll 128 it may have a consistencyof 10-25% as it enters the shoe press nip 130 between shoe press roll128 and transfer roll 132. Transfer roll 132 may be a heated roll if sodesired. Instead of a shoe press roll 128, it could be a conventionalsuction pressure roll. If a shoe press roll 128 is employed it isdesirable that roll 114 immediately prior to the shoe press roll 128 isa vacuum roll effective to remove water from the felt 126 prior to thefelt 126 entering the shoe press nip 130 since water from the furnishwill be pressed into the felt 126 in the shoe press nip 130. In anycase, using a vacuum roll at the roll 114 is typically desirable toensure the embryonic fibrous structure 122 remains in contact with thefelt 126 during the direction change as one of skill in the art willappreciate from the diagram.

The embryonic fibrous structure 122 is wet-pressed on the felt 126 inthe shoe press nip 130 with the assistance of pressure shoe 134. Theembryonic fibrous structure 122 is thus compactively dewatered at theshoe press nip 130, typically by increasing the consistency by 15 ormore points at this stage of the process. The configuration shown atshoe press nip 130 is generally termed a shoe press; in connection withthe present invention transfer roll 132 is operative as a transfercylinder which operates to convey embryonic fibrous structure 122 athigh speed, typically 1000 feet/minute (fpm) to 6000 fpm to thepatterned molding member section 106 of the present invention, forexample a creping fabric section.

Transfer roll 132 has a smooth transfer roll surface 136 which may beprovided with adhesive and/or release agents if needed. Embryonicfibrous structure 122 is adhered to transfer roll surface 136 which isrotating at a high angular velocity as the embryonic fibrous structure122 continues to advance in the machine-direction indicated by arrows138. On the transfer roll 132, embryonic fibrous structure 122 has agenerally random apparent distribution of fiber.

Embryonic fibrous structure 122 enters shoe press nip 130 typically atconsistencies of 10-25% and is dewatered and dried to consistencies offrom about 25 to about 70% by the time it is transferred to the moldingmember 140 according to the present invention, which in this case is apatterned creping fabric, as shown in the diagram.

Molding member 140 is supported on a plurality of rolls 114 and a pressnip roll 142 and forms a molding member nip 144, for example fabriccrepe nip, with transfer roll 132 as shown. The molding member 140defines a creping nip over the distance in which molding member 140 isadapted to contact transfer roll 132; that is, applies significantpressure to the embryonic fibrous structure 122 against the transferroll 132. To this end, backing (or creping) press nip roll 142 may beprovided with a soft deformable surface which will increase the lengthof the creping nip and increase the fabric creping angle between themolding member 140 and the embryonic fibrous structure 122 and the pointof contact or a shoe press roll could be used as press nip roll 142 toincrease effective contact with the embryonic fibrous structure 122 inhigh impact molding member nip 144 where embryonic fibrous structure 122is transferred to molding member 140 and advanced in themachine-direction 138. By using different equipment at the moldingmember nip 144, it is possible to adjust the fabric creping angle or thetakeaway angle from the molding member nip 144. Thus, it is possible toinfluence the nature and amount of redistribution of fiber,delamination/debonding which may occur at molding member nip 144 byadjusting these nip parameters. In some embodiments it may by desirableto restructure the z-direction interfiber characteristics while in othercases it may be desired to influence properties only in the plane of thefibrous structure. The molding member nip parameters can influence thedistribution of fiber in the fibrous structure in a variety ofdirections, including inducing changes in the z-direction as well as theMD and CD. In any case, the transfer from the transfer roll to themolding member is high impact in that the fabric is traveling slowerthan the fibrous structure and a significant velocity change occurs.Typically, the fibrous structure is creped anywhere from 10-60% and evenhigher during transfer from the transfer roll to the molding member.

Molding member nip 144 generally extends over a molding member nipdistance of anywhere from about ⅛″ to about 2″, typically ½″ to 2″. Fora molding member 140, for example creping fabric, with 32 CD strands perinch, embryonic fibrous structure 122 thus will encounter anywhere fromabout 4 to 64 weft filaments in the molding member nip 144.

The nip pressure in molding member nip 144, that is, the loading betweenroll 142 and transfer roll 132 is suitably 20-100 pounds per linear inch(PLI).

After passing through the molding member nip 144, and for example fabriccreping the embryonic fibrous structure 122, a 3D patterned fibrousstructure 146 continues to advance along MD 138 where it is wet-pressedonto Yankee cylinder (dryer) 148 in transfer nip 150. Transfer at nip150 occurs at a 3D patterned fibrous structure 146 consistency ofgenerally from about 25 to about 70%. At these consistencies, it isdifficult to adhere the 3D patterned fibrous structure 146 to the Yankeecylinder surface 152 firmly enough to remove the 3D patterned fibrousstructure 146 from the molding member 140 thoroughly. This aspect of theprocess is important, particularly when it is desired to use a highvelocity drying hood as well as maintain high impact creping conditions.

In this connection, it is noted that conventional TAD processes do notemploy high velocity hoods since sufficient adhesion to the Yankee dryeris not achieved.

It has been found in accordance with the present invention that the useof particular adhesives cooperate with a moderately moist fibrousstructure (25-70% consistency) to adhere it to the Yankee dryersufficiently to allow for high velocity operation of the system and highjet velocity impingement air drying. In this connection, a poly(vinylalcohol)/polyamide adhesive composition as noted above is applied at 154as needed.

The 3D patterned fibrous structure is dried on Yankee cylinder 148 whichis a heated cylinder and by high jet velocity impingement air in Yankeehood 156. As the Yankee cylinder 148 rotates, 3D patterned fibrousstructure 146 is creped from the Yankee cylinder 148 by creping doctorblade 158 and wound on a take-up roll 160. Creping of the paper from aYankee dryer may be carried out using an undulatory creping blade, suchas that disclosed in U.S. Pat. No. 5,690,788, the disclosure of which isincorporated by reference. Use of the undulatory crepe blade has beenshown to impart several advantages when used in production of tissueproducts. In general, tissue products creped using an undulatory bladehave higher caliper (thickness), increased CD stretch, and a higher voidvolume than do comparable tissue products produced using conventionalcrepe blades. All of these changes affected by the use of the undulatoryblade tend to correlate with improved softness perception of the tissueproducts.

When a wet-crepe process is employed, an impingement air dryer, athrough-air dryer, or a plurality of can dryers can be used instead of aYankee. Impingement air dryers are disclosed in the following patentsand applications, the disclosure of which is incorporated herein byreference: U.S. Pat. No. 5,865,955 of Ilvespaaet et al. U.S. Pat. No.5,968,590 of Ahonen et al. U.S. Pat. No. 6,001,421 of Ahonen et al. U.S.Pat. No. 6,119,362 of Sundqvist et al. U.S. patent application Ser. No.09/733,172, entitled Wet Crepe, Impingement-Air Dry Process for MakingAbsorbent Sheet, now U.S. Pat. No. 6,432,267. A throughdrying unit as iswell known in the art and described in U.S. Pat. No. 3,432,936 to Coleet al., the disclosure of which is incorporated herein by reference asis U.S. Pat. No. 5,851,353 which discloses a can-drying system.

There is shown in FIG. 11 a papermaking machine 98, similar to FIG. 10,for use in connection with the present invention. Papermaking machine 98is a three fabric loop machine having a forming section 100 generallyreferred to in the art as a crescent former. Forming section 100includes a forming wire 162 supported by a plurality of rolls such asrolls 114. The forming section 100 also includes a forming roll 166which supports paper making felt 126 such that embryonic fibrousstructure 122 is formed directly on the felt 126. Felt run 102 extendsto a shoe press section 104 wherein the moist embryonic fibrousstructure 122 is deposited on a transfer roll 132 (also referred tosometimes as a backing roll) as described above. Thereafter, embryonicfibrous structure 122 is creped onto molding member 140, such as a crepefabric, in molding member nip 144 before being deposited on Yankee dryer148 in another press nip 150. The papermaking machine 98 may include avacuum turning roll, in some embodiments; however, the three loop systemmay be configured in a variety of ways wherein a turning roll is notnecessary. This feature is particularly important in connection with therebuild of a papermachine inasmuch as the expense of relocatingassociated equipment i.e. pulping or fiber processing equipment and/orthe large and expensive drying equipment such as the Yankee dryer orplurality of can dryers would make a rebuild prohibitively expensiveunless the improvements could be configured to be compatible with theexisting facility.

FIG. 12 shows another example of a suitable papermaking process to makethe sanitary tissue products of the present invention. FIG. 12illustrates a papermaking machine 98 for use in connection with thepresent invention. Papermaking machine 98 is a three fabric loop machinehaving a forming section 100, generally referred to in the art as acrescent former. Forming section 100 includes headbox 118 depositing afurnish on forming wire 110 supported by a plurality of rolls 114. Theforming section 100 also includes a forming roll 166, which supportspapermaking felt 126, such that embryonic fibrous structure 122 isformed directly on felt 126. Felt run 102 extends to a shoe presssection 104 wherein the moist embryonic fibrous structure 122 isdeposited on a transfer roll 132 and wet-pressed concurrently with thetransfer. Thereafter, embryonic fibrous structure 122 is transferred tothe molding member section 106, by being transferred to and/or crepedonto molding member 140 of the present invention in molding member nip144, for example belt crepe nip, before being optionally vacuum drawn bysuction box 168 and then deposited on Yankee dryer 148 in another pressnip 150 using a creping adhesive, as noted above. Transfer to a Yankeedryer from the creping belt differs from conventional transfers in aconventional wet press (CWP) from a felt to a Yankee. In a CWP process,pressures in the transfer nip may be 500 PLI (87.6 kN/meter) or so, andthe pressured contact area between the Yankee surface and the fibrousstructure is close to or at 100%. The press roll may be a suction rollwhich may have a P&J hardness of 25-30. On the other hand, a belt crepeprocess of the present invention typically involves transfer to a Yankeewith 4-40% pressured contact area between the fibrous structure and theYankee surface at a pressure of 250-350 PLI (43.8-61.3 kN/meter). Nosuction is applied in the transfer nip, and a softer pressure roll isused, P&J hardness 35-45. The papermaking machine may include a suctionroll, in some embodiments; however, the three loop system may beconfigured in a variety of ways wherein a turning roll is not necessary.This feature is particularly important in connection with the rebuild ofa papermachine inasmuch as the expense of relocating associatedequipment, i.e., the headbox, pulping or fiber processing equipmentand/or the large and expensive drying equipment, such as the Yankeedryer or plurality of can dryers, would make a rebuild prohibitivelyexpensive, unless the improvements could be configured to be compatiblewith the existing facility.

NON-LIMITING EXAMPLES OF METHODS FOR MAKING SANITARY TISSUE PRODUCTSExample 1 Through-Air-Drying Belt

The following Example illustrates a non-limiting example for apreparation of a sanitary tissue product comprising a fibrous structureaccording to the present invention on a pilot-scale Fourdrinier fibrousstructure making (papermaking) machine.

An aqueous slurry of eucalyptus (Fibria Brazilian bleached hardwoodkraft pulp) pulp fibers is prepared at about 3% fiber by weight using aconventional repulper, then transferred to the hardwood fiber stockchest. The eucalyptus fiber slurry of the hardwood stock chest is pumpedthrough a stock pipe to a hardwood fan pump where the slurry consistencyis reduced from about 3% by fiber weight to about 0.15% by fiber weight.The 0.15% eucalyptus slurry is then pumped and equally distributed inthe top and bottom chambers of a multi-layered, three-chambered headboxof a Fourdrinier wet-laid papermaking machine.

Additionally, an aqueous slurry of NSK (Northern Softwood Kraft) pulpfibers is prepared at about 3% fiber by weight using a conventionalrepulper, then transferred to the softwood fiber stock chest. The NSKfiber slurry of the softwood stock chest is pumped through a stock pipeto be refined to a Canadian Standard Freeness (CSF) of about 630. Therefined NSK fiber slurry is then directed to the NSK fan pump where theNSK slurry consistency is reduced from about 3% by fiber weight to about0.15% by fiber weight. The 0.15% eucalyptus slurry is then directed anddistributed to the center chamber of a multi-layered, three-chamberedheadbox of a Fourdrinier wet-laid papermaking machine.

The wet-laid papermaking machine has a layered headbox having a topchamber, a center chamber, and a bottom chamber where the chambers feeddirectly onto the forming wire (Fourdrinier wire). The eucalyptus fiberslurry of 0.15% consistency is directed to the top headbox chamber andbottom headbox chamber. The NSK fiber slurry is directed to the centerheadbox chamber. All three fiber layers are delivered simultaneously insuperposed relation onto the Fourdrinier wire to form thereon athree-layer embryonic fibrous structure (web), of which about 38% of thetop side is made up of the eucalyptus fibers, about 38% is made of theeucalyptus fibers on the bottom side and about 24% is made up of the NSKfibers in the center. Dewatering occurs through the Fourdrinier wire andis assisted by a deflector and wire table vacuum boxes. The Fourdrinierwire is an 84M (84 by 76 5A, Albany International). The speed of theFourdrinier wire is about 750 feet per minute (fpm).

The embryonic wet fibrous structure is transferred from the Fourdrinierwire, at a fiber consistency of about 15% at the point of transfer, to a3D patterned through-air-drying belt as shown in FIGS. 6A-6C. The speedof the 3D patterned through-air-drying belt is the same as the speed ofthe Fourdrinier wire. The 3D patterned through-air-drying belt isdesigned to yield a fibrous structure as shown in FIGS. 7A and 7Bcomprising a pattern of high density knuckle regions dispersedthroughout a multi-elevational continuous pillow region. Themulti-elevational continuous pillow region comprises an intermediatedensity pillow region (density between the high density knuckles and thelow density other pillow region) and a low density pillow region formedby the deflection conduits created by the semi-continuous knuckle layersubstantially oriented in the machine direction. This 3D patternedthrough-air-drying belt is formed by casting a first layer of animpervious resin surface of semi-continuous knuckles onto a fiber meshsupporting fabric similar to that shown in FIGS. 4B and 4C and thencasting a second layer of impervious resin surface of discrete knuckles.The supporting fabric is a 98×52 filament, dual layer fine mesh. Thethickness of the first layer resin cast is about 6 mils above thesupporting fabric and the thickness of the second layer resin cast isabout 13 mils above the supporting fabric.

Further de-watering of the fibrous structure is accomplished by vacuumassisted drainage until the fibrous structure has a fiber consistency ofabout 20% to 30%.

While remaining in contact with the 3D patterned through-air-dryingbelt, the fibrous structure is pre-dried by air blow-through pre-dryersto a fiber consistency of about 53% by weight.

After the pre-dryers, the semi-dry fibrous structure is transferred to aYankee dryer and adhered to the surface of the Yankee dryer with asprayed creping adhesive. The creping adhesive is an aqueous dispersionwith the actives consisting of about 80% polyvinyl alcohol (PVA 88-50),about 20% CREPETROL® 457T20. CREPETROL® 457T20 is commercially availablefrom Hercules Incorporated of Wilmington, Del.. The creping adhesive isdelivered to the Yankee surface at a rate of about 0.15% adhesive solidsbased on the dry weight of the fibrous structure. The fiber consistencyis increased to about 97% before the fibrous structure is dry-crepedfrom the Yankee with a doctor blade.

The doctor blade has a bevel angle of about 25° and is positioned withrespect to the Yankee dryer to provide an impact angle of about 81°. TheYankee dryer is operated at a temperature of about 275° F. and a speedof about 800 fpm. The fibrous structure is wound in a roll (parent roll)using a surface driven reel drum having a surface speed of about 757fpm.

Two parent rolls of the fibrous structure are then converted into asanitary tissue product by loading the roll of fibrous structure into anunwind stand. The line speed is 400 ft/min. One parent roll of thefibrous structure is unwound and transported to an emboss stand wherethe fibrous structure is strained to form the emboss pattern in thefibrous structure and then combined with the fibrous structure from theother parent roll to make a multi-ply (2-ply) sanitary tissue product.The multi-ply sanitary tissue product is then transported over a slotextruder through which a surface chemistry may be applied. The multi-plysanitary tissue product is then transported to a winder where it iswound onto a core to form a log. The log of multi-ply sanitary tissueproduct is then transported to a log saw where the log is cut intofinished multi-ply sanitary tissue product rolls. The multi-ply sanitarytissue product of this example exhibits the properties shown in Table 1above.

Example 2 Through-Air-Drying Belt

The following Example illustrates a non-limiting example for apreparation of a sanitary tissue product comprising a fibrous structureaccording to the present invention on a pilot-scale Fourdrinier fibrousstructure making (papermaking) machine.

An aqueous slurry of eucalyptus (Fibria Brazilian bleached hardwoodkraft pulp) pulp fibers is prepared at about 3% fiber by weight using aconventional repulper, then transferred to the hardwood fiber stockchest. The eucalyptus fiber slurry of the hardwood stock chest is pumpedthrough a stock pipe to a hardwood fan pump where the slurry consistencyis reduced from about 3% by fiber weight to about 0.15% by fiber weight.The 0.15% eucalyptus slurry is then pumped and equally distributed inthe top and bottom chambers of a multi-layered, three-chambered headboxof a Fourdrinier wet-laid papermaking machine.

Additionally, an aqueous slurry of NSK (Northern Softwood Kraft) pulpfibers is prepared at about 3% fiber by weight using a conventionalrepulper, then transferred to the softwood fiber stock chest. The NSKfiber slurry of the softwood stock chest is pumped through a stock pipeto be refined to a Canadian Standard Freeness (CSF) of about 630. Therefined NSK fiber slurry is then directed to the NSK fan pump where theNSK slurry consistency is reduced from about 3% by fiber weight to about0.15% by fiber weight. The 0.15% eucalyptus slurry is then directed anddistributed to the center chamber of a multi-layered, three-chamberedheadbox of a Fourdrinier wet-laid papermaking machine.

The wet-laid papermaking machine has a layered headbox having a topchamber, a center chamber, and a bottom chamber where the chambers feeddirectly onto the forming wire (Fourdrinier wire). The eucalyptus fiberslurry of 0.15% consistency is directed to the top headbox chamber andbottom headbox chamber. The NSK fiber slurry is directed to the centerheadbox chamber. All three fiber layers are delivered simultaneously insuperposed relation onto the Fourdrinier wire to form thereon athree-layer embryonic fibrous structure (web), of which about 38% of thetop side is made up of the eucalyptus fibers, about 38% is made of theeucalyptus fibers on the bottom side and about 24% is made up of the NSKfibers in the center. Dewatering occurs through the Fourdrinier wire andis assisted by a deflector and wire table vacuum boxes. The Fourdrinierwire is an 84M (84 by 76 5A, Albany International). The speed of theFourdrinier wire is about 750 feet per minute (fpm).

The embryonic wet fibrous structure is transferred from the Fourdrinierwire, at a fiber consistency of about 15% at the point of transfer, to a3D patterned through-air-drying belt as shown in FIGS. 4A-4C. The speedof the 3D patterned through-air-drying belt is the same as the speed ofthe Fourdrinier wire. The 3D patterned through-air-drying belt isdesigned to yield a fibrous structure as shown in FIGS. 5A-5D comprisinga pattern of semi-continuous low density pillow regions andsemi-continuous high density knuckle regions. This 3D patternedthrough-air-drying belt is formed by casting an impervious resin surfaceonto a fiber mesh supporting fabric as shown in FIGS. 4B and 4C. Thesupporting fabric is a 98×52 filament, dual layer fine mesh. Thethickness of the resin cast is about 11 mils above the supportingfabric.

Further de-watering of the fibrous structure is accomplished by vacuumassisted drainage until the fibrous structure has a fiber consistency ofabout 20% to 30%.

While remaining in contact with the 3D patterned through-air-dryingbelt, the fibrous structure is pre-dried by air blow-through pre-dryersto a fiber consistency of about 53% by weight.

After the pre-dryers, the semi-dry fibrous structure is transferred to aYankee dryer and adhered to the surface of the Yankee dryer with asprayed creping adhesive. The creping adhesive is an aqueous dispersionwith the actives consisting of about 80% polyvinyl alcohol (PVA 88-50),about 20% CREPETROL® 457T20. CREPETROL® 457T20 is commercially availablefrom Hercules Incorporated of Wilmington, Del.. The creping adhesive isdelivered to the Yankee surface at a rate of about 0.15% adhesive solidsbased on the dry weight of the fibrous structure. The fiber consistencyis increased to about 97% before the fibrous structure is dry-crepedfrom the Yankee with a doctor blade.

The doctor blade has a bevel angle of about 25° and is positioned withrespect to the Yankee dryer to provide an impact angle of about 81°. TheYankee dryer is operated at a temperature of about 275° F. and a speedof about 800 fpm. The fibrous structure is wound in a roll (parent roll)using a surface driven reel drum having a surface speed of about 757fpm.

Two parent rolls of the fibrous structure are then converted into asanitary tissue product by loading the roll of fibrous structure into anunwind stand. The line speed is 400 ft/min. One parent roll of thefibrous structure is unwound and transported to an emboss stand wherethe fibrous structure is strained to form the emboss pattern in thefibrous structure and then combined with the fibrous structure from theother parent roll to make a multi-ply (2-ply) sanitary tissue product.The multi-ply sanitary tissue product is then transported over a slotextruder through which a surface chemistry may be applied. The multi-plysanitary tissue product is then transported to a winder where it iswound onto a core to form a log. The log of multi-ply sanitary tissueproduct is then transported to a log saw where the log is cut intofinished multi-ply sanitary tissue product rolls. The multi-ply sanitarytissue product of this example exhibits the properties shown in Table 1above.

Example 3 Through-Air-Drying Belt

The following Example illustrates a non-limiting example for apreparation of a sanitary tissue product comprising a fibrous structureaccording to the present invention on a pilot-scale Fourdrinier fibrousstructure making (papermaking) machine.

An aqueous slurry of eucalyptus (Fibria Brazilian bleached hardwoodkraft pulp) pulp fibers is prepared at about 3% fiber by weight using aconventional repulper, then transferred to the hardwood fiber stockchest. The eucalyptus fiber slurry of the hardwood stock chest is pumpedthrough a stock pipe to a hardwood fan pump where the slurry consistencyis reduced from about 3% by fiber weight to about 0.15% by fiber weight.The 0.15% eucalyptus slurry is then pumped and equally distributed inthe top and bottom chambers of a multi-layered, three-chambered headboxof a Fourdrinier wet-laid papermaking machine.

Additionally, an aqueous slurry of NSK (Northern Softwood Kraft) pulpfibers is prepared at about 3% fiber by weight using a conventionalrepulper, then transferred to the softwood fiber stock chest. The NSKfiber slurry of the softwood stock chest is pumped through a stock pipeto be refined to a Canadian Standard Freeness (CSF) of about 630. Therefined NSK fiber slurry is then directed to the NSK fan pump where theNSK slurry consistency is reduced from about 3% by fiber weight to about0.15% by fiber weight. The 0.15% eucalyptus slurry is then directed anddistributed to the center chamber of a multi-layered, three-chamberedheadbox of a Fourdrinier wet-laid papermaking machine.

The wet-laid papermaking machine has a layered headbox having a topchamber, a center chamber, and a bottom chamber where the chambers feeddirectly onto the forming wire (Fourdrinier wire). The eucalyptus fiberslurry of 0.15% consistency is directed to the top headbox chamber andbottom headbox chamber. The NSK fiber slurry is directed to the centerheadbox chamber. All three fiber layers are delivered simultaneously insuperposed relation onto the Fourdrinier wire to form thereon athree-layer embryonic fibrous structure (web), of which about 38% of thetop side is made up of the eucalyptus fibers, about 38% is made of theeucalyptus fibers on the bottom side and about 24% is made up of the NSKfibers in the center. Dewatering occurs through the Fourdrinier wire andis assisted by a deflector and wire table vacuum boxes. The Fourdrinierwire is an 84M (84 by 76 5A, Albany International). The speed of theFourdrinier wire is about 750 feet per minute (fpm).

The embryonic wet fibrous structure is transferred from the Fourdrinierwire, at a fiber consistency of about 15% at the point of transfer, to a3D patterned through-air-drying belt as shown in FIGS. 2A and 2B. Thespeed of the 3D patterned through-air-drying belt is the same as thespeed of the Fourdrinier wire. The 3D patterned through-air-drying beltis designed to yield a fibrous structure as shown in FIG. 3 comprising apattern of discrete high density knuckle regions dispersed throughout acontinuous low density pillow region. This 3D patternedthrough-air-drying belt is formed by casting an impervious resin surfaceonto a fiber mesh supporting fabric similar to that shown in FIGS. 4Band 4C. The supporting fabric is a 98×52 filament, dual layer fine mesh.The thickness of the resin cast is about 11 mils above the supportingfabric.

Further de-watering of the fibrous structure is accomplished by vacuumassisted drainage until the fibrous structure has a fiber consistency ofabout 20% to 30%.

While remaining in contact with the 3D patterned through-air-dryingbelt, the fibrous structure is pre-dried by air blow-through pre-dryersto a fiber consistency of about 53% by weight.

After the pre-dryers, the semi-dry fibrous structure is transferred to aYankee dryer and adhered to the surface of the Yankee dryer with asprayed creping adhesive. The creping adhesive is an aqueous dispersionwith the actives consisting of about 80% polyvinyl alcohol (PVA 88-50),about 20% CREPETROL® 457T20. CREPETROL® 457T20 is commercially availablefrom Hercules Incorporated of Wilmington, Del. The creping adhesive isdelivered to the Yankee surface at a rate of about 0.15% adhesive solidsbased on the dry weight of the fibrous structure. The fiber consistencyis increased to about 97% before the fibrous structure is dry-crepedfrom the Yankee with a doctor blade.

The doctor blade has a bevel angle of about 25° and is positioned withrespect to the Yankee dryer to provide an impact angle of about 81°. TheYankee dryer is operated at a temperature of about 275° F. and a speedof about 800 fpm. The fibrous structure is wound in a roll (parent roll)using a surface driven reel drum having a surface speed of about 757fpm.

Two parent rolls of the fibrous structure are then converted into asanitary tissue product by loading the roll of fibrous structure into anunwind stand. The line speed is 400 ft/min. One parent roll of thefibrous structure is unwound and transported to an emboss stand wherethe fibrous structure is strained to form the emboss pattern in thefibrous structure and then combined with the fibrous structure from theother parent roll to make a multi-ply (2-ply) sanitary tissue product.The multi-ply sanitary tissue product is then transported over a slotextruder through which a surface chemistry may be applied. The multi-plysanitary tissue product is then transported to a winder where it iswound onto a core to form a log. The log of multi-ply sanitary tissueproduct is then transported to a log saw where the log is cut intofinished multi-ply sanitary tissue product rolls. The multi-ply sanitarytissue product of this example exhibits the properties shown in Table 1above.

Example 4 Through-Air-Drying Belt

This following example illustrates a non-limiting example for thepreparation of a fibrous structure according to the present invention ona pilot-scale Fourdrinier paper making machine with the addition oftrichome fibers providing a strength increase.

The following Example illustrates a non-limiting example for thepreparation of sanitary tissue product comprising a fibrous structureaccording to the present invention on a pilot-scale Fourdrinier fibrousstructure making machine.

Individualized trichome fibers are first prepared from Stachys byzantinabloom stalks consisting of the dried stems, leaves, and pre-floweringbuds, by passing dried Stachys byzantina plant matter through a knifecutter (Wiley mill, manufactured by the C. W. Brabender Co. located in,NJ) equipped with an attrition screen having ¼″ holes. Exiting the Wileymill is a composite fluff constituting the individualized trichomefibers together with chunks of leaf and stem material. Theindividualized trichome fluff is then passed through an air classifier(Hosokawa Alpine 50ATP); the “accepts” or “fine” fraction from theclassifier is greatly enriched in individualized trichome fibers whilethe “rejects” or “coarse” fraction is primarily chunks of stalks, andleaf elements with only a minor fraction of individualized trichomefibers. A squirrel cage speed of 9000 rpm, an air pressure resistance of10-15 mbar, and a feed rate of about 10 g/min are used on the 50 ATP.The resulting individualized trichome material (fines) is mixed with a10% aqueous dispersion of “Texcare 4060” to add about 10% by weight“Texcare 4060” by weight of the bone dry weight of the individualizedtrichomes followed by slurrying the “Texcare”-treated trichome in waterat 3% consistency using a conventional repulper. This slurry is passedthrough a stock pipe toward another stock pipe containing a eucalyptusfiber slurry.

Special care must be taken while processing the trichomes. 60 lbs. oftrichome fiber is pulped in a 50 gallon pulper by adding water in halfamount required to make a 1% trichome fiber slurry. This is done toprevent trichome fibers over flowing and floating on surface of thewater due to lower density and hydrophobic nature of the trichome fiber.After mixing and stirring a few minutes, the pulper is stopped and theremaining trichome fibers are pushed in while water is added. After pHadjustment, it is pulped for 20 minutes, then dumped in a separate chestfor delivery onto the machine headbox. This allows one to place trichomefibers in one or more layers, alone or mixed with other fibers, such ashardwood fibers and/or softwood fibers.

The aqueous slurry of eucalyptus fibers is prepared at about 3% byweight using a conventional repulper. This slurry is also passed througha stock pipe toward the stock pipe containing the trichome fiber slurry.

The 1% trichome fiber slurry is combined with the 3% eucalyptus fiberslurry in a proportion which yields about 13.3% trichome fibers and86.7% eucalyptus fibers. The stockpipe containing the combined trichomeand eucalyptus fiber slurries is directed toward the wire layer ofheadbox of a Fourdrinier machine.

Separately, an aqueous slurry of NSK fibers of about 3% by weight ismade up using a conventional repulper.

In order to impart temporary wet strength to the finished fibrousstructure, a 1% dispersion of temporary wet strengthening additive(e.g., Parez® commercially available from Kemira) is prepared and isadded to the NSK fiber stock pipe at a rate sufficient to deliver 0.3%temporary wet strengthening additive based on the dry weight of the NSKfibers. The absorption of the temporary wet strengthening additive isenhanced by passing the treated slurry through an in-line mixer.

The trichome fiber and eucalyptus fiber slurry is diluted with whitewater at the inlet of a fan pump to a consistency of about 0.15% basedon the total weight of the eucalyptus and trichome fiber slurry. The NSKfibers, likewise, are diluted with white water at the inlet of a fanpump to a consistency of about 0.15% based on the total weight of theNSK fiber slurry. The eucalyptus/trichome fiber slurry and the NSK fiberslurry are both directed to a layered headbox capable of maintaining theslurries as separate streams until they are deposited onto a formingfabric on the Fourdrinier.

The fibrous structure making machine has a layered headbox having a topchamber, a center chamber, and a bottom chamber. The eucalyptus/trichomecombined fiber slurry is pumped through the top headbox chamber,eucalyptus fiber slurry is pumped through the bottom headbox chamber,and, simultaneously, the NSK fiber slurry is pumped through the centerheadbox chamber and delivered in superposed relation onto theFourdrinier wire to form thereon a three-layer embryonic fibrousstructure, of which about 83% is made up of the eucalyptus/trichomefibers and 17% is made up of the NSK fibers. Dewatering occurs throughthe Fourdrinier wire and is assisted by a deflector and vacuum boxes.The Fourdrinier wire is of a 5-shed, satin weave configuration having 87machine-direction and 76 cross-machine-direction monofilaments per inch,respectively. The speed of the Fourdrinier wire is about 750 fpm (feetper minute).

The embryonic wet fibrous structure is transferred from the Fourdrinierwire, at a fiber consistency of about 15% at the point of transfer, to a3D patterned through-air-drying belt comprising semi-continuous knucklesand semi-continous pillows, similar to the first layer of thethrough-air-drying belt shown in FIGS. 6A-6C. The speed of the 3Dpatterned through-air-drying belt is the same as the speed of theFourdrinier wire. The 3D patterned through-air-drying belt is designedto yield a fibrous structure comprising a pattern of semi-continuoushigh density knuckle regions dispersed throughout a continuous lowdensity pillow region. This 3D patterned through-air-drying belt isformed by casting an impervious resin surface onto a fiber meshsupporting fabric similar to that shown in FIGS. 4B and 4C. Thesupporting fabric is a 98×52 filament, dual layer fine mesh. Thethickness of the resin cast is about 11 mils above the supportingfabric.

Further de-watering of the fibrous structure is accomplished by vacuumassisted drainage until the fibrous structure has a fiber consistency ofabout 20% to 30%.

While remaining in contact with the 3D patterned through-air-dryingbelt, the fibrous structure is pre-dried by air blow-through pre-dryersto a fiber consistency of about 65% by weight.

After the pre-dryers, the semi-dry fibrous structure is transferred tothe Yankee dryer and adhered to the surface of the Yankee dryer with asprayed creping adhesive. The creping adhesive is an aqueous dispersionwith the actives consisting of about 22% polyvinyl alcohol, about 11%CREPETROL® A3025, and about 67% CREPETROL® R6390. CREPETROL® A3025 andCREPETROL® R6390 are commercially available from Hercules Incorporatedof Wilmington, Del. The creping adhesive is delivered to the Yankeesurface at a rate of about 0.15% adhesive solids based on the dry weightof the fibrous structure. The fiber consistency is increased to about97% before the fibrous structure is dry creped from the Yankee with adoctor blade.

The doctor blade has a bevel angle of about 25° and is positioned withrespect to the Yankee dryer to provide an impact angle of about 81degrees. The Yankee dryer is operated at a temperature of about 350° F.(177° C.) and a speed of about 800 fpm. The fibrous structure is woundin a roll using a surface driven reel drum having a surface speed ofabout 656 feet per minute.

Two parent rolls of the fibrous structure are then converted into asanitary tissue product by loading the roll of fibrous structure into anunwind stand. The line speed is 400 ft/min. One parent roll of thefibrous structure is unwound and transported to an emboss stand wherethe fibrous structure is strained to form the emboss pattern in thefibrous structure and then combined with the fibrous structure from theother parent roll to make a multi-ply (2-ply) sanitary tissue product.The multi-ply sanitary tissue product is then transported over a slotextruder through which a surface chemistry may be applied. The multi-plysanitary tissue product is then transported to a winder where it iswound onto a core to form a log. The log of multi-ply sanitary tissueproduct is then transported to a log saw where the log is cut intofinished multi-ply sanitary tissue product rolls. The multi-ply sanitarytissue product of this example exhibits the properties shown in Table 1,above.

Example 5 Through-Air-Drying Belt

The following Example illustrates a non-limiting example for apreparation of a sanitary tissue product comprising a fibrous structureaccording to the present invention on a pilot-scale Fourdrinier fibrousstructure making (papermaking) machine.

An aqueous slurry of eucalyptus (Fibria Brazilian bleached hardwoodkraft pulp) pulp fibers is prepared at about 3% fiber by weight using aconventional repulper, then transferred to the hardwood fiber stockchest. The eucalyptus fiber slurry of the hardwood stock chest is pumpedthrough a stock pipe to a hardwood fan pump where the slurry consistencyis reduced from about 3% by fiber weight to about 0.15% by fiber weight.The 0.15% eucalyptus slurry is then pumped and equally distributed inthe top and bottom chambers of a multi-layered, three-chambered headboxof a Fourdrinier wet-laid papermaking machine.

Additionally, an aqueous slurry of NSK (Northern Softwood Kraft) pulpfibers is prepared at about 3% fiber by weight using a conventionalrepulper, then transferred to the softwood fiber stock chest. The NSKfiber slurry of the softwood stock chest is pumped through a stock pipeto be refined to a Canadian Standard Freeness (CSF) of about 630. Therefined NSK fiber slurry is then directed to the NSK fan pump where theNSK slurry consistency is reduced from about 3% by fiber weight to about0.15% by fiber weight. The 0.15% NSK slurry is then directed anddistributed to the center chamber of a multi-layered, three-chamberedheadbox of a Fourdrinier wet-laid papermaking machine.

In order to impart temporary wet strength to the finished fibrousstructure, a 1% dispersion of temporary wet strengthening additive(e.g., Fennorez® 91 commercially available from Kemira) is prepared andis added to the NSK fiber stock pipe at a rate sufficient to deliver0.23% temporary wet strengthening additive based on the dry weight ofthe NSK fibers. The absorption of the temporary wet strengtheningadditive is enhanced by passing the treated slurry through an in-linemixer.

The wet-laid papermaking machine has a layered headbox having a topchamber, a center chamber, and a bottom chamber where the chambers feeddirectly onto the forming wire (Fourdrinier wire). The eucalyptus fiberslurry of 0.15% consistency is directed to the top headbox chamber andbottom headbox chamber. The NSK fiber slurry is directed to the centerheadbox chamber. All three fiber layers are delivered simultaneously insuperposed relation onto the Fourdrinier wire to form thereon athree-layer embryonic fibrous structure (web), of which about 26% of thetop side is made up of the eucalyptus fibers, about 26% is made of theeucalyptus fibers on the bottom side and about 48% is made up of the NSKfibers in the center. Dewatering occurs through the Fourdrinier wire andis assisted by a deflector and wire table vacuum boxes. The Fourdrinierwire is an 84M (84 by 76 5A, Albany International). The speed of theFourdrinier wire is about 800 feet per minute (fpm). The one-ply BasisWeight for this condition was 11.3 pounds per 3000 square feet. Theone-ply caliper (at 95 gsi) was 10.65 mils.

The embryonic wet fibrous structure is transferred from the Fourdrinierwire, at a fiber consistency of about 18-22% at the point of transfer,to a 3D patterned through-air-drying belt as shown in FIGS. 6A-6C. Thespeed of the 3D patterned through-air-drying belt is the same as thespeed of the Fourdrinier wire. The 3D patterned through-air-drying beltis designed to yield a fibrous structure as shown in FIGS. 7A and 7Bcomprising a pattern of high density knuckle regions dispersedthroughout a multi-elevational continuous pillow region. Themulti-elevational continuous pillow region comprises an intermediatedensity pillow region (density between the high density knuckles and thelow density other pillow region) and a low density pillow region formedby the deflection conduits created by the semi-continuous knuckle layersubstantially oriented in the machine direction. This 3D patternedthrough-air-drying belt is formed by casting a first layer of animpervious resin surface of semi-continuous knuckles onto a fiber meshsupporting fabric similar to that shown in FIGS. 4B and 4C and thencasting a second layer of impervious resin surface of discrete knuckles.The supporting fabric is a 98×52 filament, dual layer fine mesh. Thethickness of the first layer resin cast is about 6 mils above thesupporting fabric and the thickness of the second layer resin cast isabout 13 mils above the supporting fabric.

Further de-watering of the fibrous structure is accomplished by vacuumassisted drainage until the fibrous structure has a fiber consistency ofabout 20% to 30%.

While remaining in contact with the 3D patterned through-air-dryingbelt, the fibrous structure is pre-dried by air blow-through pre-dryersto a fiber consistency of about 50-65% by weight.

After the pre-dryers, the semi-dry fibrous structure is transferred to aYankee dryer and adhered to the surface of the Yankee dryer with asprayed creping adhesive. The creping adhesive is an aqueous dispersionwith the actives consisting of about 80% polyvinyl alcohol (PVA 88-44),about 20% UNICREPE® 457T20. UNICREPE® 457T20 is commercially availablefrom GP Chemicals. The creping adhesive is delivered to the Yankeesurface at a rate of about 0.15% adhesive solids based on the dry weightof the fibrous structure. The fiber consistency is increased to about96-98% before the fibrous structure is dry-creped from the Yankee with adoctor blade.

The doctor blade has a bevel angle of about 25° and is positioned withrespect to the Yankee dryer to provide an impact angle of about 81°. TheYankee dryer is operated at a temperature of about 300° F. and a speedof about 800 fpm. The fibrous structure is wound in a roll (parent roll)using a surface driven reel drum having a surface speed of about 655fpm.

Two parent rolls of the fibrous structure are then converted into asanitary tissue product by loading the roll of fibrous structure into anunwind stand. The line speed is 400 ft/min. One parent roll of thefibrous structure is unwound and transported to an emboss stand wherethe fibrous structure is strained to form the emboss pattern in thefibrous structure via a 0.75″ Pressure Roll Nip and then combined withthe fibrous structure from the other parent roll to make a multi-ply(2-ply) sanitary tissue product. The multi-ply sanitary tissue productis then transported to a winder where it is wound onto a core to form alog. The log of multi-ply sanitary tissue product is then transported toa log saw where the log is cut into finished multi-ply sanitary tissueproduct rolls. The multi-ply sanitary tissue product of this exampleexhibits the properties shown in Table 1, above.

Example 6 Through-Air-Drying Belt

The following Example illustrates a non-limiting example for apreparation of a sanitary tissue product comprising a fibrous structureaccording to the present invention on a pilot-scale Fourdrinier fibrousstructure making (papermaking) machine.

An aqueous slurry of eucalyptus (Fibria Brazilian bleached hardwoodkraft pulp) pulp fibers is prepared at about 3% fiber by weight using aconventional repulper, then transferred to the hardwood fiber stockchest. The eucalyptus fiber slurry of the hardwood stock chest is pumpedthrough a stock pipe to a hardwood fan pump where the slurry consistencyis reduced from about 3% by fiber weight to about 0.15% by fiber weight.The 0.15% eucalyptus slurry is then pumped and equally distributed inthe top and bottom chambers of a multi-layered, three-chambered headboxof a Fourdrinier wet-laid papermaking machine.

Additionally, an aqueous slurry of NSK (Northern Softwood Kraft) pulpfibers is prepared at about 3% fiber by weight using a conventionalrepulper, then transferred to the softwood fiber stock chest. The NSKfiber slurry of the softwood stock chest is pumped through a stock pipeto be refined to a Canadian Standard Freeness (CSF) of about 630. Therefined NSK fiber slurry is then directed to the NSK fan pump where theNSK slurry consistency is reduced from about 3% by fiber weight to about0.15% by fiber weight. The 0.15% NSK slurry is then directed anddistributed to the center chamber of a multi-layered, three-chamberedheadbox of a Fourdrinier wet-laid papermaking machine.

In order to impart temporary wet strength to the finished fibrousstructure, a 1% dispersion of temporary wet strengthening additive(e.g., Fennorez® 91 commercially available from Kemira) is prepared andis added to the NSK fiber stock pipe at a rate sufficient to deliver0.23% temporary wet strengthening additive based on the dry weight ofthe NSK fibers. The absorption of the temporary wet strengtheningadditive is enhanced by passing the treated slurry through an in-linemixer.

The wet-laid papermaking machine has a layered headbox having a topchamber, a center chamber, and a bottom chamber where the chambers feeddirectly onto the forming wire (Fourdrinier wire). The eucalyptus fiberslurry of 0.15% consistency is directed to the top headbox chamber andbottom headbox chamber. The NSK fiber slurry is directed to the centerheadbox chamber. All three fiber layers are delivered simultaneously insuperposed relation onto the Fourdrinier wire to form thereon athree-layer embryonic fibrous structure (web), of which about 26% of thetop side is made up of the eucalyptus fibers, about 26% is made of theeucalyptus fibers on the bottom side and about 48% is made up of the NSKfibers in the center. Dewatering occurs through the Fourdrinier wire andis assisted by a deflector and wire table vacuum boxes. The Fourdrinierwire is an 84M (84 by 76 5A, Albany International). The speed of theFourdrinier wire is about 800 feet per minute (fpm). The one-ply BasisWeight for this condition was 11.5 pounds per 3000 square feet. Theone-ply caliper (at 95 gsi) was 23.1 mils.

The embryonic wet fibrous structure is transferred from the Fourdrinierwire, at a fiber consistency of about 18-22% at the point of transfer,to a 3D patterned through-air-drying belt as shown in FIGS. 6A-6C. Thespeed of the 3D patterned through-air-drying belt is the same as thespeed of the Fourdrinier wire. The 3D patterned through-air-drying beltis designed to yield a fibrous structure as shown in FIGS. 7A and 7Bcomprising a pattern of high density knuckle regions dispersedthroughout a multi-elevational continuous pillow region. Themulti-elevational continuous pillow region comprises an intermediatedensity pillow region (density between the high density knuckles and thelow density other pillow region) and a low density pillow region formedby the deflection conduits created by the semi-continuous knuckle layersubstantially oriented in the machine direction. This 3D patternedthrough-air-drying belt is formed by casting a first layer of animpervious resin surface of semi-continuous knuckles onto a fiber meshsupporting fabric similar to that shown in FIGS. 4B and 4C and thencasting a second layer of impervious resin surface of discrete knuckles.The supporting fabric is a 98×52 filament, dual layer fine mesh. Thethickness of the first layer resin cast is about 6 mils above thesupporting fabric and the thickness of the second layer resin cast isabout 13 mils above the supporting fabric.

Further de-watering of the fibrous structure is accomplished by vacuumassisted drainage until the fibrous structure has a fiber consistency ofabout 20% to 30%.

While remaining in contact with the 3D patterned through-air-dryingbelt, the fibrous structure is pre-dried by air blow-through pre-dryersto a fiber consistency of about 50-65% by weight.

After the pre-dryers, the semi-dry fibrous structure is transferred to aYankee dryer and adhered to the surface of the Yankee dryer with asprayed creping adhesive. The creping adhesive is an aqueous dispersionwith the actives consisting of about 80% polyvinyl alcohol (PVA 88-44),about 20% UNICREPE® 457T20. UNICREPE® 457T20 is commercially availablefrom GP Chemicals. The creping adhesive is delivered to the Yankeesurface at a rate of about 0.15% adhesive solids based on the dry weightof the fibrous structure. The fiber consistency is increased to about96-98% before the fibrous structure is dry-creped from the Yankee with adoctor blade.

The doctor blade has a bevel angle of about 25° and is positioned withrespect to the Yankee dryer to provide an impact angle of about 81°. TheYankee dryer is operated at a temperature of about 300° F. and a speedof about 800 fpm. The fibrous structure is wound in a roll (parent roll)using a surface driven reel drum having a surface speed of about 671fpm.

Two parent rolls of the fibrous structure are then converted into asanitary tissue product by loading the roll of fibrous structure into anunwind stand. The line speed is 400 ft/min. One parent roll of thefibrous structure is unwound and transported to an emboss stand wherethe fibrous structure is strained to form the emboss pattern in thefibrous structure via a 0.75″ Pressure Roll Nip and then combined withthe fibrous structure from the other parent roll to make a multi-ply(2-ply) sanitary tissue product. The multi-ply sanitary tissue productis then transported to a winder where it is wound onto a core to form alog. The log of multi-ply sanitary tissue product is then transported toa log saw where the log is cut into finished multi-ply sanitary tissueproduct rolls. The multi-ply sanitary tissue product of this exampleexhibits the properties shown in Table 1, above.

Example 7 Through-Air-Drying Belt

The following Example illustrates a non-limiting example for apreparation of a sanitary tissue product, for example a paper towel,comprising a fibrous structure according to the present invention on apilot-scale Fourdrinier fibrous structure making (papermaking) machine.

A 3% by weight aqueous slurry of northern softwood kraft (NSK) pulp ismade up in a conventional re-pulper. The NSK slurry is refined gentlyand a 3% solution of a permanent wet strength resin (i.e. Kymene 5221marketed by Hercules incorporated of Wilmington, Del.) is added to theNSK stock pipe at a rate of 1% by weight of the dry fibers. Theadsorption of Kymene 5221 to NSK is enhanced by an in-line mixer. A 1%solution of Carboxy Methyl Cellulose (CMC) (i.e. FinnFix 700 marketed byC.P. Kelco U.S. Inc. of Atlanta, Ga.) is added after the in-line mixerat a rate of 0.35% by weight of the dry fibers to enhance the drystrength of the fibrous substrate. The refined NSK fiber slurry is thendirected to the NSK fan pump where the NSK slurry consistency is reducedfrom about 3% by fiber weight to about 0.15% by fiber weight. The 0.15%NSK slurry is then directed and distributed to the center and topchamber of a multi-layered, three-chambered headbox of a Fourdrinierwet-laid papermaking machine.

A 3% by weight aqueous slurry of Eucalyptus fibers is made up in aconventional re-pulper. A 1% solution of defoamer (i.e. Wickit 1285marketed by Hercules Incorporated of Wilmington, Del.) is added to theEucalyptus stock pipe at a rate of 0.1% by weight of the dry fibers andits adsorption is enhanced by an in-line mixer. The eucalyptus fiberslurry of the hardwood stock chest is pumped through a stock pipe to theNSK fan pump where the slurry consistency is reduced from about 3% byfiber weight to about 0.15% by fiber weight. The 0.15% eucalyptus slurryis then pumped and equally distributed in the center and top chambers ofa multi-layered, three-chambered headbox of a Fourdrinier wet-laidpapermaking machine. The eucalyptus fiber slurry of the hardwood stockchest is pumped through a stock pipe to the Euc fan pump where theslurry consistency is reduced from about 3% by fiber weight to about0.15% by fiber weight. The 0.15% Eucalyptus slurry is then pumped anddistributed in the bottom chamber of a multi-layered, three-chamberedheadbox of a Fourdrinier wet-laid papermaking machine.

A 3% by weight aqueous slurry of 40% Eucalyptus fibers, 40% NorthernSoftwood Kraft (NSK), and 20% Southern Softwood Kraft (SSK) is made upin a conventional re-pulper. This blend will be called mixed fiber. Thefiber slurry of the mixed fiber stock chest is pumped through a stockpipe to the NSK fan pump where the slurry consistency is reduced fromabout 3% by fiber weight to about 0.15% by fiber weight. The 0.15% mixedfiber slurry is then pumped and equally distributed in the center andtop chambers of a multi-layered, three-chambered headbox of aFourdrinier wet-laid papermaking machine.

The wet-laid papermaking machine has a layered headbox having a topchamber, a center chamber, and a bottom chamber where the chambers feeddirectly onto the forming wire (Fourdrinier wire). The eucalyptus fiberslurry of 0.15% consistency is directed to the top headbox chamber andin equal amounts to the center and bottom chambers. The NSK fiber slurryis directed to the center and bottom headbox chamber. The Mixed Fiberslurry is directed to the center and bottom headbox chamber. All threefiber layers are delivered simultaneously in superposed relation ontothe Fourdrinier wire to form thereon a three-layer embryonic fibrousstructure (web), of which about 21% of the bottom side is made up of theeucalyptus fibers, about 11% is made of the eucalyptus fibers on thecenter and top side, about 53% is made up of the NSK fibers in thecenter and top side, about 15% is made up of Mixed Fiber in the centerand top side. Dewatering occurs through the Fourdrinier wire and isassisted by a deflector and wire table vacuum boxes. The Fourdrinierwire is an 84M (84 by 76 5A, Albany International). The speed of theFourdrinier wire is about 700 feet per minute (fpm).

The web is then transferred to the patterned transfer/imprinting fabric,with a pattern as described in this application, in the transfer zonewithout precipitating substantial densification of the web. The web isthen forwarded, at a second velocity, V₂, on the transfer/imprintingfabric along a looped path in contacting relation with a transfer headdisposed at the transfer zone, the second velocity being from about 5%to about 40% slower than the first velocity. Since the wire speed isfaster than the transfer/imprinting fabric, wet shortening of the weboccurs at the transfer point. Thus, the wet web foreshortening may beabout 3% to about 15%.

Further de-watering is accomplished by vacuum assisted drainage untilthe web has a fiber consistency of about 20% to about 30%. The patternedweb is pre-dried by air blow-through to a fiber consistency of about 65%by weight. The web is then adhered to the surface of a Yankee dryer witha sprayed creping adhesive comprising 0.1% aqueous solution of PolyvinylAlcohol (PVA). The fiber consistency is increased to an estimated 96%before the dry creping the web with a doctor blade. The doctor blade hasa bevel angle of about 45 degrees and is positioned with respect to theYankee dryer to provide an impact angle of about 101 degrees. The driedweb is reeled at a fourth velocity, V₄, that is faster than the thirdvelocity, V₃, of the drying cylinder.

Two plies of the web can be formed into multi-ply sanitary tissueproducts by embossing and laminating them together using PVA adhesive.The multi-ply sanitary tissue product of this example exhibits theproperties shown in Table 1, above.

Test Methods

Unless otherwise specified, all tests described herein including thosedescribed under the Definitions section and the following test methodsare conducted on samples that have been conditioned in a conditionedroom at a temperature of 23° C.±1.0° C. and a relative humidity of50%±2% for a minimum of 2 hours prior to the test. The samples testedare “usable units.” “Usable units” as used herein means sheets, flatsfrom roll stock, pre-converted flats, and/or single or multi-plyproducts. All tests are conducted in such conditioned room. Do not testsamples that have defects such as wrinkles, tears, holes, and like. Allinstruments are calibrated according to manufacturer's specifications.

Basis Weight Test Method

Basis weight of a fibrous structure and/or sanitary tissue product ismeasured on stacks of twelve usable units using a top loading analyticalbalance with a resolution of ±0.001 g. The balance is protected from airdrafts and other disturbances using a draft shield. A precision cuttingdie, measuring 3.500 in±0.0035 in by 3.500 in±0.0035 in is used toprepare all samples.

With a precision cutting die, cut the samples into squares. Combine thecut squares to form a stack twelve samples thick. Measure the mass ofthe sample stack and record the result to the nearest 0.001 g.

The Basis Weight is calculated in lbs/3000 ft² or g/m² as follows:

Basis Weight=(Mass of stack)/[(Area of 1 square in stack)×(No. ofsquares in stack)]

For example,

Basis Weight (lbs/3000 ft²)=[[Mass of stack (g)/453.6 (g/lbs)]/[12.25(in²)/144 (in²/ft²)×12]]×3000

or,

Basis Weight (g/m²)=Mass of stack (g)/[79.032 (cm²)/10,000 (cm²/m²)×12]

Report result to the nearest 0.1 lbs/3000 ft² or 0.1 g/m². Sampledimensions can be changed or varied using a similar precision cutter asmentioned above, so as at least 100 square inches of sample area instack.

Caliper Test Method

Caliper of a fibrous structure and/or sanitary tissue product ismeasured using a ProGage Thickness Tester (Thwing-Albert InstrumentCompany, West Berlin, N.J.) with a pressure foot diameter of 2.00 inches(area of 3.14 in²) at a pressure of 95 g/in². Four (4) samples areprepared by cutting of a usable unit such that each cut sample is atleast 2.5 inches per side, avoiding creases, folds, and obvious defects.An individual specimen is placed on the anvil with the specimen centeredunderneath the pressure foot. The foot is lowered at 0.03 in/sec to anapplied pressure of 95 g/in². The reading is taken after 3 sec dwelltime, and the foot is raised. The measure is repeated in like fashionfor the remaining 3 specimens. The caliper is calculated as the averagecaliper of the four specimens and is reported in mils (0.001 in) to thenearest 0.1 mils.

Density Test Method

The density of a fibrous structure and/or sanitary tissue product iscalculated as the quotient of the Basis Weight of a fibrous structure orsanitary tissue product expressed in lbs/3000 ft2 divided by the Caliper(at 95 g/in²) of the fibrous structure or sanitary tissue productexpressed in mils. The final Density value is calculated in lbs/ft3and/or g/cm3, by using the appropriate converting factors.

Stack Compressibility and Resilient Bulk Test Method

Stack thickness (measured in mils, 0.001 inch) is measured as a functionof confining pressure (g/in²) using a Thwing-Albert (14 W. CollingsAve., West Berlin, N.J.) Vantage Compression/Softness Tester (model1750-2005 or similar) or equivalent instrument, equipped with a 2500 gload cell (force accuracy is +/−0.25% when measuring value is between10%-100% of load cell capacity, and 0.025% when measuring value is lessthan 10% of load cell capacity), a 1.128 inch diameter steel pressurefoot (one square inch cross sectional area) which is aligned parallel tothe steel anvil (2.5 inch diameter). The pressure foot and anvilsurfaces must be clean and dust free, particularly when performing thesteel-to-steel test. Thwing-Albert software (MAP) controls the motionand data acquisition of the instrument.

The instrument and software is set-up to acquire crosshead position andforce data at a rate of 50 points/sec. The crosshead speed (which movesthe pressure foot) for testing samples is set to 0.20 inches/min (thesteel-to-steel test speed is set to 0.05 inches/min). Crosshead positionand force data are recorded between the load cell range of approximately5 and 1500 grams during compression. The crosshead is programmed to stopimmediately after surpassing 1500 grams, record the thickness at thispressure (termed Tmax), and immediately reverse direction at the samespeed as performed in compression. Data is collected during thisdecompression portion of the test (also termed recovery) betweenapproximately 1500 and 5 grams. Since the foot area is one square inch,the force data recorded corresponds to pressure in units of g/in². TheMAP software is programmed to the select 15 crosshead position values(for both compression and recovery) at specific pressure trap points of10, 25, 50, 75, 100, 125, 150, 200, 300, 400, 500, 600, 750, 1000, and1250 g/in² (i.e., recording the crosshead position of very next acquireddata point after the each pressure point trap is surpassed). In additionto these 30 collected trap points, T_(max) is also recorded, which isthe thickness at the maximum pressure applied during the test(approximately 1500 g/in²).

Since the overall test system, including the load cell, is not perfectlyrigid, a steel-to-steel test is performed (i.e., nothing in between thepressure foot and anvil) at least twice for each batch of testing, toobtain an average set of steel-to-steel crosshead positions at each ofthe 31 trap points described above. This steel-to-steel crossheadposition data is subtracted from the corresponding crosshead positiondata at each trap point for each tested stacked sample, therebyresulting in the stack thickness (mils) at each pressure trap pointduring the compression, maximum pressure, and recovery portions of thetest.

StackT (trap)=StackCP (trap)−SteelCP (trap)

Where:

trap=trap point pressure at either compression, recovery, or max

StackT=Thickness of Stack (at trap pressure)

StackCP=Crosshead position of Stack in test (at trap pressure)

Steel CP=Crosshead position of steel-to-steel test (at trap pressure)

A stack of five (5) usable units thick is prepared for testing asfollows. The minimum usable unit size is 2.5 inch by 2.5 inch; however alarger sheet size is preferable for testing, since it allows for easierhandling without touching the central region where compression testingtakes place. For typical perforated rolled bath tissue, this consists ofremoving five (5) sets of 3 connected usable units. In this case,testing is performed on the middle usable unit, and the outer 2 usableunits are used for handling while removing from the roll and stacking.For other product formats, it is advisable, when possible, to create atest sheet size (each one usable unit thick) that is large enough suchthat the inner testing region of the created 5 usable unit thick stackis never physically touched, stretched, or strained, but with dimensionsthat do not exceed 14 inches by 6 inches.

The 5 sheets (one usable unit thick each) of the same approximatedimensions, are placed one on top the other, with their MD aligned inthe same direction, their outer face all pointing in the same direction,and their edges aligned +/−3 mm of each other. The central portion ofthe stack, where compression testing will take place, is never to bephysically touched, stretched, and/or strained (this includes never to‘smooth out’ the surface with a hand or other apparatus prior totesting).

The 5 sheet stack is placed on the anvil, positioning it such that thepressure foot will contact the central region of the stack (for thefirst compression test) in a physically untouched spot, leaving spacefor a subsequent (second) compression test, also in the central regionof the stack, but separated by ¼ inch or more from the first compressiontest, such that both tests are in untouched, and separated spots in thecentral region of the stack. From these two tests, an average crossheadposition of the stack at each trap pressure (i.e., StackCP(trap)) iscalculated for compression, maximum pressure, and recovery portions ofthe tests. Then, using the average steel-to-steel crosshead trap points(i.e., SteelCP(trap)), the average stack thickness at each trap (i.e.,StackT(trap) is calculated (mils).

Stack Compressibility is defined here as the absolute value of thelinear slope of the stack thickness (mils) as a function of the log(10)of the confining pressure (grams/in²), by using the 15 compression trappoints discussed previously (i.e., compression from 10 to 1250 g/in²),in a least squares regression. The units for Stack Compressibility aremils/(log(g/in²)), and is reported to the nearest 0.1 mils/(log(g/in²)).

Resilient Bulk is calculated from the stack weight per unit area and thesum of 8 StackT(trap) thickness values from the maximum pressure andrecovery portion of the tests: i.e., at maximum pressure (T_(max)) andrecovery trap points at R1250, R1000, R750, R500, R300, R100, and R10g/in² (a prefix of “R” denotes these traps come from recovery portion ofthe test). Stack weight per unit area is measured from the same regionof the stack contacted by the compression foot, after the compressiontesting is complete, by cutting a 3.50 inch square (typically) with aprecision die cutter, and weighing on a calibrated 3-place balance, tothe nearest 0.001 gram. The weight of the precisely cut stack, alongwith the StackT(trap) data at each required trap pressure (each pointbeing an average from the two compression/recovery tests discussedpreviously), are used in the following equation to calculate ResilientBulk, reported in units of cm³/g, to the nearest 0.1 cm³/g.

${{Resilient}\mspace{14mu} {Bulk}} = \frac{\begin{matrix}{{SUM}\left( {{StackT}\left( {T_{\max},{R\; 1250},{R\; 1000},} \right.} \right.} \\{\left. \left. {{R\; 750},{R\; 500},{R\; 300},{R\; 100},{R\; 10}} \right) \right)*0.00254}\end{matrix}}{M/A}$

Where:

StackT=Thickness of Stack (at trap pressures of Tmax and recoverypressures listed above), (mils)

M=weight of precisely cut stack, (grams)

A=area of the precisely cut stack, (cm²)

Plate Stiffness Test Method

As used herein, the “Plate Stiffness” test is a measure of stiffness ofa flat sample as it is deformed downward into a hole beneath the sample.For the test, the sample is modeled as an infinite plate with thickness“t” that resides on a flat surface where it is centered over a hole withradius “R”. A central force “F” applied to the tissue directly over thecenter of the hole deflects the tissue down into the hole by a distance“w”. For a linear elastic material the deflection can be predicted by:

$w = {\frac{3\; F}{4\pi \; {Et}^{3}}\left( {1 - v} \right)\left( {3 + v} \right)R^{2}}$

where “E” is the effective linear elastic modulus, “v” is the Poisson'sratio, “R” is the radius of the hole, and “t” is the thickness of thetissue, taken as the caliper in millimeters measured on a stack of 5tissues under a load of about 0.29 psi. Taking Poisson's ratio as 0.1(the solution is not highly sensitive to this parameter, so theinaccuracy due to the assumed value is likely to be minor), the previousequation can be rewritten for “w” to estimate the effective modulus as afunction of the flexibility test results:

$E \approx {\frac{3R^{2}}{4\; t^{3}}\frac{F}{w}}$

The test results are carried out using an MTS Alliance RT/1, InsightRenew, or similar model testing machine (MTS Systems Corp., EdenPrairie, Minn.), with a 50 newton load cell, and data acquisition rateof at least 25 force points per second. As a stack of five tissue sheets(created without any bending, pressing, or straining) at least2.5-inches by 2.5 inches, but no more than 5.0 inches by 5.0 inches,oriented in the same direction, sits centered over a hole of radius15.75 mm on a support plate, a blunt probe of 3.15 mm radius descends ata speed of 20 mm/min. For typical perforated rolled bath tissue, samplepreparation consists of removing five (5) connected usable units, andcarefully forming a 5 sheet stack, accordion style, by bending only atthe perforation lines. When the probe tip descends to 1 mm below theplane of the support plate, the test is terminated. The maximum slope(using least squares regression) in grams of force/mm over any 0.5 mmspan during the test is recorded (this maximum slope generally occurs atthe end of the stroke). The load cell monitors the applied force and theposition of the probe tip relative to the plane of the support plate isalso monitored. The peak load is recorded, and “E” is estimated usingthe above equation.

The Plate Stiffness “S” per unit width can then be calculated as:

$S = \frac{{Et}^{3}}{12}$

and is expressed in units of Newtons*millimeters. The Testworks programuses the following formula to calculate stiffness (or can be calculatedmanually from the raw data output):

$S = {\left( \frac{F}{w} \right)\left\lbrack \frac{\left( {3 + v} \right)R^{2}}{16\pi} \right\rbrack}$

wherein “F/w” is max slope (force divided by deflection), “v” isPoisson's ratio taken as 0.1, and “R” is the ring radius.

The same sample stack (as used above) is then flipped upside down andretested in the same manner as previously described. This test is runthree more times (with different sample stacks). Thus, eight S valuesare calculated from four 5-sheet stacks of the same sample. Thenumerical average of these eight S values is reported as Plate Stiffnessfor the sample.

Slip Stick Coefficient of Friction Test Method

Background

Friction is the force resisting the relative motion of solid surfaces,fluid layers, and material elements sliding against each other. Ofparticular interest here, ‘dry’ friction resists relative lateral motionof two solid surfaces in contact. Dry friction is subdivided into staticfriction between non-moving surfaces, and kinetic friction betweenmoving surfaces. “Slip Stick”, as applied here, is the term used todescribe the dynamic variation in kinetic friction.

Friction is not itself a fundamental force but arises from fundamentalelectromagnetic forces between the charged particles constituting thetwo contacting surfaces. Textured surfaces also involve mechanicalinteractions, as is the case when sandpaper drags against a fibroussubstrate. The complexity of these interactions makes the calculation offriction from first principles impossible and necessitates the use ofempirical methods for analysis and the development of theory. As such, aspecific sled material and test method was identified, and has showncorrelation to human perception of surface feel.

This Slip Stick Coefficient of Friction Test Method measures theinteraction of a diamond file (120-140 grit) against a surface of a testsample, in this case a fibrous structure and/or sanitary tissue product,at a pressure of about 32 g/in² as shown in FIGS. 13-15. The frictionmeasurements are highly dependent on the exactness of the sled materialsurface properties, and since each sled has no ‘standard’ reference,sled-to-sled surface property variation is accounted for by testing atest sample with multiple sleds, according to the equipment andprocedure described below.

Equipment and Set-Up

A Thwing-Albert (14 W. Collings Ave., West Berlin, N.J.) friction/peeltest instrument (model 225-1) or equivalent if no longer available, isused, equipped with data acquisition software and a calibrated 2000 gramload cell that moves horizontally across the platform. Attached to theload cell is a small metal fitting (defined here as the “load cell arm”)which has a small hole near its end, such that a sled string can beattached (for this method, however, no string will be used). Into thisload cell arm hole, insert a cap screw (¾ inch #8-32) by partiallyscrewing it into the opening, so that it is rigid (not loose) andpointing vertically, perpendicular to the load cell arm.

After turning instrument on, set instrument test speed to 2 inches/min,test time to 10 seconds, and wait at least 5 minutes for instrument towarm up before re-zeroing the load cell (with nothing touching it) andtesting. Force data from the load cell is acquired at a rate of 52points per second, reported to the nearest 0.1 gram force. Press the‘Return’ button to move crosshead 201 to its home position.

A smooth surfaced metal test platform 200, with dimensions of 5 inchesby 4 inches by ¾ inch thick, is placed on top of the test instrumentplaten surface, on the left hand side of the load cell 203, with one ofits 4 inch by ¾ inch sides facing towards the load cell 203, positioned1.125 inches d from the left most tip of the load cell arm 202 as shownin FIGS. 13 and 15.

Sixteen test sleds 204 are required to perform this test (32 differentsled surface faces). Each is made using a dual sided, wide faced diamondfile 206 (25mm×25mm, 120/140 grit, 1.2mm thick, McMaster-Carr partnumber 8142A14) with 2 flat metal washers 208 (approximately 11/16thinch outer diameter and about 11/32nd inch inner diameter). The combinedweight of the diamond file 206 and 2 washers 208 is 11.7 grams +/−0.2grams (choose different washers until weight is within this range).Using a metal bonding adhesive (Loctite 430, or similar), adhere the 2washers 208 to the c-shaped end 210 of the diamond file 206 (one each oneither face), aligned and positioned such that the opening 212 is largeenough for the cap screw 214 to easily fit into, and to make the totallength of sled 204 to approximately 3 inches long. Clean sled 204 bydipping it, diamond face end 216 only, into an acetone bath, while atthe same time gently brushing with soft bristled toothbrush 3-6 times onboth sides of the diamond file 206. Remove from acetone and pat dry eachside with Kimwipe tissue (do not rub tissue on diamond surface, sincethis could break tissue pieces onto sled surface). Wait at least 15minutes before using sled 204 in a test. Label each side of the sled 204(on the arm or washer, not on the diamond face) with a unique identifier(i.e., the first sled is labeled “1 a” on one side, and “1 b” on itsother side). When all 16 sleds 204 are created and labeled, there arethen 32 different diamond face surfaces for available for testing,labeled 1 a and 1 b through 16 a and 16 b. These sleds 204 must betreated as fragile (particularly the diamond surfaces) and handledcarefully; thus, they are stored in a slide box holder, or similarprotective container.

Sample Prep

If sample to be tested is bath tissue, in perforated roll form, thengently remove 8 sets of 2 connected sheets from the roll, touching onlythe corners (not the regions where the test sled will contact). Usescissors or other sample cutter if needed. If sample is in another form,cut 8 sets of sample approximately 8 inches long in the MD, byapproximately 4 inches long in the CD, one usable unit thick each. Makenote and/or a mark that differentiates both face sides of each sample(e.g., fabric side or wire side, top or bottom, etc.). When sample prepis complete, there are 8 sheets prepared with appropriate marking thatdifferentiates one side from the other. These will be referred tohereinafter as: sheets #1 through #8, each with a top side and a bottomside.

Test Operation

Press the ‘Return’ button to ensure crosshead 201 is in its homeposition.

Without touching test area of sample, place sheet #1 218 on testplatform 200, top side facing up, aligning one of the sheet's CD edges(i.e. edge that is parallel to the CD) along the platform 218 edgeclosest to the load cell 202 (+/−1 mm). This first test (pull), of 32total, will be in the MD direction on the top side of the sheet 218.Place a brass bar weight or equivalent 220 (1 inch diameter, 3.75 incheslong) on the sheet 218, near its center, aligned perpendicular to thesled pull direction, to prevent sheet 218 from moving during the test.Place test sled “1 a” 204 over cap screw head 214 (i.e., sled washeropening 212 over cap screw head 214, and sled side 1 a is facing down)such that the diamond file 206 surface is laying flat and parallel onthe sheet 218 surface and the cap screw 214 is touching the inside edgeof the washers 208.

Gently place a cylindrically shaped brass 20 gram (+/−0.01 grams) weight222 on top of the sled 204, with its edge aligned and centered with thesled's back end. Initiate the sled movement m and data acquisition bypressing the ‘Test’ button on the instrument. The test set up is shownin FIG. 15. The computer collects the force (grams) data and, afterapproximately 10 seconds of test time, this first of 32 test pulls ofthe overall test is complete.

If the test pull was set-up correctly, the diamond file 206 face (25mmby 25mm square) stays in contact with the sheet 218 during the entire 10second test time (i.e., does not overhang over the sheet 218 or testplatform 200 edge). Also, if at any time during the test the sheet 218moves, the test is invalid, and must be rerun on another untouchedportion of the sheet 218, using a heavier brass bar weight or equivalent220 to hold sheet 218 down. If the sheet 218 rips or tears, rerun thetest on another untouched portion of the sheet 218 (or create a newsheet 218 from the sample). If it rips again, then replace the sled 204with a different one (giving it the same sled name as the one itreplaced). These statements apply to all 32 test pulls.

For the second of 32 test pulls (also an MD pull, but in the oppositedirection on the sheet), first remove the 20 gram weight 222, the sled204, and the brass bar weight or equivalent 220 from the sheet 218.Press the ‘Return’ button on the instrument to reset the crosshead 201to its home position. Rotate the sheet 218 180° (with top side stillfacing up), and replace the brass bar weight or equivalent 220 onto thesheet 218 (in the same position described previously). Place test sled“1 b” 204 over the cap screw head 214 (i.e., sled washer opening 212over cap screw head 214, and sled side 1 b is facing down) and the 20gram weight 222 on the sled 204, in the same manner as describedpreviously. Press the ‘Test’ button to collect the data for the secondtest pull.

The third test pull will be in the CD direction. After removing the sled204, weights 220, 222, and returning the crosshead 201, the sheet 218 isrotated 90° from its previous position (with top side still facing up),and positioned so that its MD edge is aligned with the test platform 200edge (+/−1 mm). Position the sheet 218 such that the sled 204 will nottouch any perforation, if present, or touch the area where the brass barweight or equivalent 220 rested in previous test pulls. Place the brassbar weight or equivalent 220 onto the sheet 218 near its center, alignedperpendicular to the sled pull direction m. Place test sled “2 a” 204over the cap screw head 214 (i.e., sled washer opening 212 over capscrew head 214, and sled side 2 a is facing down) and the 20 gram weight222 on the sled 204, in the same manner as described previously. Pressthe ‘Test’ button to collect the data for the third test pull.

The fourth test pull will also be in the CD, but in the oppositedirection and on the opposite half section of the sheet 218. Afterremoving the sled 204, weights 220, 222, and returning the crosshead201, the sheet 218 is rotated 180° from its previous position (with topside still facing up), and positioned so that its MD edge is againaligned with the test platform 200 edge (+/−1 mm). Position the sheet218 such that the sled 204 will not touch any perforation, if present,or touch the area where the brass bar weight or equivalent 220 rested inprevious test pulls. Place the brass bar weight or equivalent 220 ontothe sheet 218 near its center, aligned perpendicular to the sled pulldirection m. Place test sled “2 b” 204 over the cap screw head 214(i.e., sled washer opening 212 over cap screw head 214, and sled side 2b is facing down) and the 20 gram weight 222 on the sled 204, in thesame manner as described previously. Press the ‘Test’ button to collectthe data for the fourth test pull.

After the fourth test pull is complete, remove the sled 204, weights220, 222, and return the crosshead 201 to the home position. Sheet #1218 is discarded.

Test pulls 5-8 are performed in the same manner as 1-4, except thatsheet #2 218 has its bottom side now facing upward, and sleds 3 a, 3 b,4 a, and 4 b are used.

Test pulls 9-12 are performed in the same manner as 1-4, except thatsheet #3 218 has its top side facing upward, and sleds 5 a, 5 b, 6 a,and 6 b are used.

Test pulls 13-16 are performed in the same manner as 1-4, except thatsheet #4 218 has its bottom side facing upward, and sleds 7a, 7b, 8a,and 8b are used.

Test pulls 17-20 are performed in the same manner as 1-4, except thatsheet #5 218 has its top side facing upward, and sleds 9 a, 9 b, 10 a,and 10 b are used.

Test pulls 21-24 are performed in the same manner as 1-4, except thatsheet #6 218 has its bottom side facing upward, and sleds 11 a, 11 b, 12a, and 12 b are used.

Test pulls 25-28 are performed in the same manner as 1-4, except thatsheet #7 218 has its top side facing upward, and sleds 13a, 13b, 14a,and 14b are used.

Test pulls 29-32 are performed in the same manner as 1-4, except thatsheet #8 218 has its bottom side facing upward, and sleds 15a, 15b, 16a,and 16b are used.

Calculations and Results

The collected force data (grams) is used to calculate Slip Stick COF foreach of the 32 test pulls, and subsequently the overall average SlipStick COF for the sample being tested. In order to calculate Slip StickCOF for each test pull, the following calculations are made. First, thestandard deviation is calculated for the force data centered on 131stdata point (which is 2.5 seconds after the start of the test) +/−26 datapoints (i.e., the 53 data points that cover the range from 2.0 to 3.0seconds). This standard deviation calculation is repeated for eachsubsequent data point, and stopped after the 493rd point (about 9.5sec). The numerical average of these 363 standard deviation values isthen divided by the sled weight (31.7 g) and multiplied by 10,000 togenerate the Slip Stick COF*10,000 for each test pull. This calculationis repeated for all 32 test pulls. The numerical average of these 32Slip Stick COF*10,000 values is the reported value of the Slip StickCOF*10,000 for the sample. For simplicity, it is referred to as justSlip Stick COF, or more simply as Slip Stick, without units(dimensionless), and is reported to the nearest 1.0.

Outliers and Noise

It is not uncommon, with this described method, to observe about one outof the 32 test pulls to exhibit force data with a harmonic wave ofvibrations superimposed upon it. For whatever reason, the pulled sledperiodically gets into a relatively high frequency, oscillating‘shaking’ mode, which can be seen in graphed force vs. time. The sinewave-like noise was found to have a frequency of about 10 sec-1 andamplitude in the 3-5 grams force range. This adds a bias to the trueSlip Stick result for that test; thus, it is appropriate for this testpull be treated as an outlier, the data removed, and replaced with a newtest of that same scenario (e.g., CD top face) and sled number (e.g. 3a).

To get an estimate of the overall measurement noise, ‘blanks’ were runon the test instrument without any touching the load cell (i.e., nosled). The average force from these tests is zero grams, but thecalculated Slip Stick COF was 66. Thus, it is speculated that, for thisinstrument measurement system, this value represents that absolute lowerlimit for Slip Stick COF.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A sanitary tissue product roll comprising asanitary tissue product comprising a plurality of pulp fibers, whereinthe sanitary tissue product exhibits a Compressibility of greater than46.0 mils/(log(g/in²)) as measured according to the StackCompressibility and Resilient Bulk Test Method and a Plate Stiffness ofless than 5.20 N*mm as measured according to the Plate Stiffness TestMethod.
 2. The sanitary tissue product roll according to claim 1 whereinthe pulp fibers comprise wood pulp fibers.
 3. The sanitary tissueproduct roll according to claim 1 wherein the pulp fibers comprisenon-wood pulp fibers.
 4. The sanitary tissue product roll according toclaim 1 wherein the sanitary tissue product comprises an embossedfibrous structure ply.
 5. The sanitary tissue product roll according toclaim 1 wherein the sanitary tissue product comprises a 3D patternedfibrous structure ply.
 6. The sanitary tissue product roll according toclaim 5 wherein the 3D patterned fibrous structure ply comprises athrough-air-dried fibrous structure ply.
 7. The sanitary tissue productroll according to claim 5 wherein the 3D patterned fibrous structure plycomprises a fabric creped fibrous structure ply.
 8. The sanitary tissueproduct roll according to claim 5 wherein the 3D patterned fibrousstructure ply comprises a belt creped fibrous structure ply.
 9. Thesanitary tissue product roll according to claim 1 wherein the sanitarytissue product comprises a conventional wet-pressed fibrous structureply.
 10. A sanitary tissue product roll comprising a sanitary tissueproduct comprising at least one creped through-air-dried fibrousstructure ply, wherein the sanitary tissue product exhibits aCompressibility of greater than 36.0 mils/(log(g/in²)) as measuredaccording to the Stack Compressibility and Resilient Bulk Test Methodand a Plate Stiffness of less than 5.20 N*mm as measured according tothe Plate Stiffness Test Method.
 11. The sanitary tissue product rollaccording to claim 10 wherein the pulp fibers comprise wood pulp fibers.12. The sanitary tissue product roll according to claim 10 wherein thepulp fibers comprise non-wood pulp fibers.
 13. A sanitary tissue productroll comprising a multi-ply sanitary tissue product comprising at leastone 3D patterned fibrous structure ply comprising a plurality of pulpfibers, wherein the multi-ply sanitary tissue product exhibits aCompressibility of greater than 36.0 mils/(log(g/in²)) as measuredaccording to the Stack Compressibility and Resilient Bulk Test Methodand a Plate Stiffness of less than 5.20 N*mm as measured according tothe Plate Stiffness Test Method.
 14. The sanitary tissue product rollaccording to claim 13 wherein the pulp fibers comprise wood pulp fibers.15. The sanitary tissue product roll according to claim 13 wherein thepulp fibers comprise non-wood pulp fibers.
 16. The sanitary tissueproduct roll according to claim 13 wherein the 3D patterned fibrousstructure ply is an embossed 3D patterned fibrous structure ply.
 17. Thesanitary tissue product roll according to claim 16 wherein the 3Dpatterned fibrous structure ply is a 3D patterned through-air-driedfibrous structure ply.
 18. The sanitary tissue product roll according toclaim 17 wherein the 3D patterned through-air-dried fibrous structureply is a non-lotioned through-air-dried fibrous structure ply.
 19. Thesanitary tissue product roll according to claim 16 wherein the 3Dpatterned fibrous structure ply comprises a fabric creped fibrousstructure ply.
 20. The sanitary tissue product roll according to claim16 wherein the 3D patterned through-air-dried fibrous structure ply is abelt creped fibrous structure ply.